Systems and methods for measuring voltage and current within a welding torch

ABSTRACT

A retrofit module includes at least one of a current sensing component that has a first circuit or a voltage sensing component that has a second circuit. The current sensing component and the voltage sensing component may be disposed in a torch head of a welding or plasma cutting torch. The current sensing component is configured to measure a welding or plasma cutting current of the torch head, and the voltage sensing component is configured to measure a welding or plasma cutting voltage of the torch head.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation application of U.S. Non-Provisionalpatent application Ser. No. 14/245,870 entitled “Systems and Methods forMeasuring Voltage and Current within a Welding Torch” filed Apr. 4,2014, which is herein incorporated by reference in its entirety.

BACKGROUND

The invention relates generally to welding and, more particularly, tosystems and methods for measuring voltage and current within a weldingtorch.

Welding is a process that has increasingly become utilized in variousindustries and applications. Such processes may be automated in certaincontexts, although a large number of applications continue to exist formanual welding operations. In both cases, such welding operations relyon a variety of types of equipment to ensure the supply of weldingconsumables (e.g., wire feed, shielding gas, etc.) is provided to theweld in appropriate amounts at the desired time.

In preparation for performing manual welding operations, weldingoperators may be trained using a welding system (e.g., a weldingtraining system). The welding system may be designed to train weldingoperators with the proper techniques for performing various weldingoperations. Certain welding systems may use various training methods. Asmay be appreciated, these training systems may be expensive to acquireand operate. Accordingly, welding training institutions may only acquirea limited number of such training systems. Furthermore, certain weldingsystems may not adequately train welding operators to perform highquality welds.

BRIEF DESCRIPTION

In one embodiment, a welding or plasma cutting torch may include avoltage sensing component at least partially disposed in a body of thewelding or plasma cutting torch. The voltage sensing component hasvoltage sensing circuitry and is configured to measure a welding orplasma cutting voltage of the welding or plasma cutting torch.

In another embodiment, a welding or plasma cutting torch may include acurrent sensing component at least partially disposed in a body of thewelding or plasma cutting torch. The current sensing component hascurrent sensing circuitry and is configured to measure the welding orplasma cutting current of the welding or plasma cutting torch.

In another embodiment, a retrofit module may include at least one of acurrent sensing component that has a first circuit or a voltage sensingcomponent that has a second circuit. The current sensing component andthe voltage sensing component may be at least partially disposed in abody of a welding or plasma cutting torch. The current sensing componentis configured to measure a welding or plasma cutting current of thewelding or plasma cutting torch, and the voltage sensing component isconfigured to measure a welding or plasma cutting voltage of the weldingor plasma cutting torch.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a block diagram of an embodiment of a welding system inaccordance with aspects of the present disclosure;

FIG. 2 is a block diagram of an embodiment of portions of the weldingsystem of FIG. 1 in accordance with aspects of the present disclosure;

FIG. 2A is a schematic diagram of an embodiment of circuitry of thewelding torch of FIG. 1 in accordance with aspects of the presentdisclosure;

FIG. 3 is a perspective view of an embodiment of the welding torch ofFIG. 1 in accordance with aspects of the present disclosure;

FIG. 4 is a perspective view of an embodiment of the welding stand ofFIG. 1 in accordance with aspects of the present disclosure;

FIG. 5 is a perspective view of an embodiment of a calibration device inaccordance with aspects of the present disclosure;

FIG. 6 is a perspective view of an embodiment of a fixture assembly inaccordance with aspects of the present disclosure;

FIG. 7 is a perspective view of a welding wire stickout calibration toolin accordance with aspects of the present disclosure;

FIG. 8 is a top view of the welding wire stickout calibration tool ofFIG. 7 in accordance with aspects of the present disclosure;

FIG. 9 is an embodiment of a method for calibrating wire stickout from awelding torch in accordance with aspects of the present disclosure;

FIG. 10 is a perspective view of an embodiment of a welding consumablehaving physical marks in accordance with aspects of the presentdisclosure;

FIG. 11 is a perspective view of an embodiment of welding wire havingphysical marks in accordance with aspects of the present disclosure;

FIG. 12 is a perspective view of an embodiment of a vertical armassembly of the welding stand of FIG. 1 in accordance with aspects ofthe present disclosure;

FIG. 13 is a perspective view of an embodiment of an overhead weldingarm assembly in accordance with aspects of the present disclosure;

FIG. 14 is a block diagram of an embodiment of welding software havingmultiple training modes in accordance with aspects of the presentdisclosure;

FIG. 15 is a block diagram of an embodiment of a virtually reality modeof welding software in accordance with aspects of the presentdisclosure;

FIG. 16 is an embodiment of a method for integrating training resultsdata in accordance with aspects of the present disclosure;

FIG. 17 is an embodiment of a chart illustrating multiple sets ofwelding data for a welding operator in accordance with aspects of thepresent disclosure;

FIG. 18 is an embodiment of a chart illustrating welding data for awelder compared to welding data for a class in accordance with aspectsof the present disclosure;

FIG. 19 is a block diagram of an embodiment of a data storage system forstoring certification status data in accordance with aspects of thepresent disclosure;

FIG. 20 is an embodiment of a screen illustrating data corresponding toa weld in accordance with aspects of the present disclosure;

FIG. 21 is an embodiment of a screen illustrating a discontinuityanalysis of a weld in accordance with aspects of the present disclosure;

FIG. 22 is a block diagram of an embodiment of a welding instructorscreen of welding software in accordance with aspects of the presentdisclosure;

FIG. 23 is an embodiment of a method for weld training using augmentedreality in accordance with aspects of the present disclosure;

FIG. 24 is an embodiment of another method for weld training usingaugmented reality in accordance with aspects of the present disclosure;

FIG. 25 is a block diagram of an embodiment of a welding torch inaccordance with aspects of the present disclosure;

FIG. 26 is an embodiment of a method for providing vibration feedback toa welding operator using a welding torch in accordance with aspects ofthe present disclosure;

FIG. 27 is a graph of an embodiment of two patterns each including adifferent frequency for providing vibration feedback to a weldingoperator in accordance with aspects of the present disclosure;

FIG. 28 is a graph of an embodiment of two patterns each including adifferent modulation for providing vibration feedback to a weldingoperator in accordance with aspects of the present disclosure;

FIG. 29 is a graph of an embodiment of two patterns each including adifferent amplitude for providing vibration feedback to a weldingoperator in accordance with aspects of the present disclosure;

FIG. 30 is a perspective view of an embodiment of a welding torch havingspherical markers that may be used for tracking the welding torch inaccordance with aspects of the present disclosure;

FIG. 31 is an embodiment of a method for displaying on a display of awelding torch a welding parameter in relation to a threshold inaccordance with aspects of the present disclosure;

FIG. 32 is an embodiment of a set of screenshots of a display of awelding torch for showing a welding parameter in relation to a thresholdin accordance with aspects of the present disclosure;

FIG. 33 is an embodiment of a method for tracking a welding torch in awelding system using at least four markers in accordance with aspects ofthe present disclosure;

FIG. 34 is an embodiment of a method for detecting the ability for aprocessor to communicate with a welding torch in accordance with aspectsof the present disclosure;

FIG. 35 is an embodiment of a method for calibrating a curved weld jointthat may be used with a welding system in accordance with aspects of thepresent disclosure;

FIG. 36 is a diagram of an embodiment of a curved weld joint inaccordance with aspects of the present disclosure;

FIG. 37 is an embodiment of a method for tracking a multi-pass weldingoperation in accordance with aspects of the present disclosure;

FIG. 38 is a perspective view of an embodiment of a welding stand inaccordance with aspects of the present disclosure;

FIG. 39 is a cross-sectional view of an embodiment of a welding surfaceof the welding stand of FIG. 38 in accordance with aspects of thepresent disclosure;

FIG. 40 is a cross-sectional view of an embodiment of a sensing devicehaving a removable cover in accordance with aspects of the presentdisclosure;

FIG. 41 is a perspective view of an embodiment of a calibration tool inaccordance with aspects of the present disclosure;

FIG. 42 is a perspective view of the calibration tool of FIG. 41 havingan outer cover removed in accordance with aspects of the presentdisclosure;

FIG. 43 is a side view of an embodiment of a pointed tip of acalibration tool in accordance with aspects of the present disclosure;

FIG. 44 is a side view of an embodiment of a rounded tip of acalibration tool in accordance with aspects of the present disclosure;

FIG. 45 is a side view of an embodiment of a rounded tip of acalibration tool having a small pointed tip in accordance with aspectsof the present disclosure;

FIG. 46 is an embodiment of a method for detecting a calibration pointin accordance with aspects of the present disclosure;

FIG. 47 is an embodiment of a method for determining a welding scorebased on a welding path in accordance with aspects of the presentdisclosure;

FIG. 48 is an embodiment of a method for transitioning between weldingmodes using a user interface of a welding torch in accordance withaspects of the present disclosure;

FIG. 49 is a perspective view of an embodiment of the voltage sensingcomponent and the current sensing component within a welding torch inaccordance with aspects of the present disclosure;

FIG. 50 is a side view of an embodiment of the voltage sensing componentwithin a welding system in accordance with aspects of the presentdisclosure;

FIG. 51 is a schematic of an embodiment of the voltage sensing circuitrywithin the voltage sensing component in accordance with aspects of thepresent disclosure;

FIG. 52 is a side view of an embodiment of the current sensing componentwithin a welding system in accordance with aspects of the presentdisclosure;

FIG. 53 is a diagram of the operation of a Hall sensor of the currentsensing component in accordance with aspects of the present disclosure;

FIG. 54 is a schematic of an embodiment of the current sensing circuitrywithin the current sensing component in accordance with aspects of thepresent disclosure;

FIG. 55 is a perspective view of an embodiment of the current sensingcomponent within a welding torch in accordance with aspects of thepresent disclosure;

FIG. 56 is an exploded view of an embodiment of the current sensingcomponent in relation to a welding conductor of the welding torch inaccordance with aspects of the present disclosure; and

FIG. 57 is a top view of an embodiment of a retrofit kit in accordancewith aspects of the present disclosure.

DETAILED DESCRIPTION

In welding training systems, a variety of parameters related to awelding operation may be measured and conveyed to the operator as someform of feedback. These parameters may include the welding voltage andwelding current of the welding operation. However, existing trainingsystems do not directly measure the welding voltage and welding currentconveyed through a conductor within the welding torch. At best, existingwelding systems may include a power supply that measures the voltage andcurrent within the power supply.

The embodiments described herein include a voltage sensing component anda current sensing component disposed in a welding torch that may be usedto directly measure the welding voltage and the welding current withinthe welding torch. The voltage sensing component may include two leads,one coupled to the welding conductor and the other coupled to a secondconductor within the welding system. The voltage sensing component maydetermine the welding voltage by computing the difference between thevoltages of the welding conductor and the second conductor. The currentsensing component includes a Hall sensor that measures a Hall voltagethat is representative of the welding current and uses the Hall voltageto determine the welding current. The voltage sensing component and thecurrent sensing component also include circuitry that converts (e.g.,scales) the welding voltage and the welding current, respectively, to asignal suitable for input to a computer system, for example, as afeedback signal. The voltage sensing component and the current sensingcomponent described herein may also be packaged as a retrofit kit, whichmay be installed in existing welding torches.

Turning now to FIG. 1, a block diagram of an embodiment of a weldingsystem 10 is depicted. As used herein, a welding system may include anysuitable welding related system, including, but not limited to, awelding training system, a live welding system, a simulated weldingsystem, a virtual reality welding system, and so forth. It should benoted that, while primarily described herein as being a welding system10, it will be appreciated that in other embodiments, the welding system10 may indeed be any welding-type system, such as a plasma cuttingsystem, or any other system where an arc may be delivered via a torch toperform a welding-type operation, such as welding, plasma cutting, andso forth. The welding system 10 includes a welding stand 12 forproviding support for various training devices. For example, the stand12 may be configured to support a welding surface, a workpiece, afixture, one or more training arms, and so forth. The welding system 10also includes a welding torch 14 that may be used by a welding operator(e.g., welding student) to perform welding operations (e.g., trainingoperations). As described in greater detail below, the welding torch 14may be configured with a user interface configured to receive inputsfrom the welding operator, control circuitry configured to process theinputs, and a communication interface configured to provide the inputsto another device. Furthermore, the welding torch 14 may include one ormore display and/or indicators to provide data to the welding operator.Moreover, the welding system 10 includes a sensing device 16 (e.g.,sensor, sensing assembly, and so forth) used to sense a position of oneor more welding devices and/or to sense an orientation of one or morewelding devices. For example, the sensing device 16 may be used to sensea position and/or an orientation of the stand 12, the welding torch 14,a welding surface, a workpiece, a fixture, one or more training arms,and so forth. The sensing device 16 may include any suitable sensingdevice, such as a motion sensing device or a motion tracking device.Furthermore, the sensing device 16 may include one or more cameras, suchas one or more infrared cameras, one or more visible spectrum cameras,one or more high dynamic range (HDR) cameras, and so forth.

The sensing device 16 is communicatively coupled to a computer 18. Thesensing device 16 is configured to provide data (e.g., image data,sensed data, six degrees of freedom (6DOF) data, etc.) to the computer18. Furthermore, the sensing device 16 may be configured to receive data(e.g., configuration data, setup data, commands, register settings,etc.) from the computer 18. The computer 18 includes one or moreprocessors 20, memory devices 22, and storage devices 24. Theprocessor(s) 20 may be used to execute software, such as weldingsoftware, image processing software, sensing device software, and soforth. Moreover, the processor(s) 20 may include one or moremicroprocessors, such as one or more “general-purpose” microprocessors,one or more special-purpose microprocessors and/or application specificintegrated circuits (ASICS), or some combination thereof. For example,the processor(s) 20 may include one or more reduced instruction set(RISC) processors.

The storage device(s) 24 (e.g., nonvolatile storage) may include ROM,flash memory, a hard drive, or any other suitable optical, magnetic, orsolid-state storage medium, or a combination thereof. The storagedevice(s) 24 may store data (e.g., data corresponding to a weldingoperation, video and/or parameter data corresponding to a weldingoperation, etc.), instructions (e.g., software or firmware for thewelding system, the sensing device 16, etc.), and any other suitabledata. As will be appreciated, data that corresponds to a weldingoperation may include a video recording of the welding operation, asimulated video, an orientation of the welding torch 14, a position ofthe welding torch 14, a work angle, a travel angle, a distance between acontact tip of the welding torch 14 and a workpiece, a travel speed, aproximity, a voltage, a current, a traversed path, a discontinuityanalysis, welding device settings, and so forth.

The memory device(s) 22 may include a volatile memory, such as randomaccess memory (RAM), and/or a nonvolatile memory, such as read-onlymemory (ROM). The memory device(s) 22 may store a variety of informationand may be used for various purposes. For example, the memory device(s)22 may store processor-executable instructions (e.g., firmware orsoftware) for the processor(s) 20 to execute, such as instructions for awelding training simulation and/or for the sensing device 16. Inaddition, a variety of control regimes for various welding processes,along with associated settings and parameters may be stored in thestorage device(s) 24 and/or memory device(s) 22, along with codeconfigured to provide a specific output (e.g., initiate wire feed,enable gas flow, capture welding current data, detect short circuitparameters, determine amount of spatter, etc.) during operation. Thewelding power supply 28 may be used to provide welding power to alive-arc welding operation, and the wire feeder 30 may be used toprovide welding wire to the live-arc welding operation.

The welding system 10 includes a display 32 for displaying data and/orscreens associated with welding (e.g., to display data corresponding toa welding software). For example, the display 32 may provide a graphicaluser interface to a welding operator (e.g., welding instructor, weldingstudent). The graphical user interface may provide various screens toenable the welding instructor to organize a class, provide assignmentsto the class, analyze assignments performed by the class, provideassignments to an individual, analyze assignments performed by theindividual, add, change, and/or delete parameters for a weldingassignment, and so forth. Furthermore, the graphical user interface mayprovide various screens to enable a welding operator (e.g., weldingstudent) to perform a welding assignment, view results from priorwelding assignments, and so forth. In certain embodiments, the display32 may be a touch screen display configured to receive touch inputs, andto provide data corresponding to the touch inputs to the computer 18.

An external display 34 is coupled to the computer 18 to enable anindividual located remotely from the welding system 10 to view datacorresponding to the welding system 10. Furthermore, a network device 36is coupled to the computer 18 to enable the computer 18 to communicatewith other devices connected to the Internet or another network 38(e.g., for providing test results to another device and/or for receivingtest results from another device). For example, the network device 36may enable the computer 18 to communicate with an external weldingsystem 40, a production welding system 42, and/or a remote computer 44.As may be appreciated, the welding system 10 described herein may beused to train welding students in a cost effective manner. Furthermore,the welding system 10 is configured to integrate real welding withsimulated welding in a manner that prepares welding students for highquality production welding.

FIG. 2 is a block diagram of an embodiment of portions of the weldingsystem 10 of FIG. 1. As illustrated, a power distribution assembly 46provides power to the welding torch 14 and the computer 18. Moreover,the welding torch 14 includes control circuitry 52 configured to controlthe operation of the welding torch 14. In the illustrated embodiment,the control circuitry 52 includes one or more processors 54, memorydevices 56, and storage devices 58. In other embodiments, the controlcircuitry 52 may not include the processors 54, the memory devices 56,and/or the storage devices 58. The processor(s) 54 may be used toexecute software, such as welding torch software. Moreover, theprocessor(s) 54 may be similar to the processor(s) 20 describedpreviously. Furthermore, the memory device(s) 56 may be similar to thememory device(s) 22, and the storage device(s) 58 may be similar to thestorage device(s) 24.

The welding torch 14 includes a user interface 60 to enable a weldingoperator (e.g., welding student, welding instructor, etc.) to interactwith the welding torch 14 and/or to provide inputs to the welding torch14. For example, the user interface 60 may include buttons, switches,touch screens, touchpads, and so forth. The inputs provided to thewelding torch 14 by the welding operator may be provided to the computer18. For example, the inputs provided to the welding torch 14 may be usedto control welding software being executed by the computer 18. As such,the welding operator may use the user interface 60 on the welding torch14 to navigate the welding software screens, setup procedures, dataanalysis, welding courses, make selections within the welding software,configure the welding software, and so forth. Thus, the welding operatorcan use the welding torch 14 to control the welding software (e.g., thewelding operator does not have to put down the welding torch 14 to use adifferent input device). The welding torch 14 also includes visualindicators 61, such as a display 62 and LEDs 64. The visual indicators61 may be configured to indicate or display data and/or imagescorresponding to a weld, welding training, and/or welding software. Forexample, the visual indicators 61 may be configured to indicate awelding torch orientation, a welding torch travel speed, a welding torchposition, a contact tip to workpiece distance, a proximity of thewelding torch 14 in relation to the workpiece, an aim of the weldingtorch 14 (e.g., at what point the welding torch 14 is directed),training information for the welding operator, and so forth. Moreover,the visual indicators 61 may be configured to provide visual indicationsbefore a weld, during a weld, and/or after a weld. In certainembodiments, the LEDs 64 may illuminate to facilitate their detection bythe sensing device 16. In such embodiments, the LEDs 64 may bepositioned to enable the sensing device 16 to determine a positionand/or an orientation of the welding torch 14 based on a spatialposition of the LEDs 64.

In certain embodiments, the welding torch 14 includes power conversioncircuitry 66 configured to receive power from the data reporting device26 (e.g., or another device), and to convert the received power forpowering the welding torch 14. In certain embodiments, the welding torch14 may receive power that is already converted and/or does not utilizepower conversion. Moreover, in some embodiments, the welding torch 14may be powered by a battery or any suitable powering mechanism. Thewelding torch 14 also includes a communication interface 68 (e.g.,RS-232 driver) to facilitate communication between the welding torch 14and the data reporting device 26 (or another device). In the illustratedembodiment, the welding torch 14 may communicate with the computer 18 byproviding data to the data reporting device 26 using the communicationinterfaces 50 and 68, then the data reporting device 26 communicates thedata to the computer 18. Accordingly, inputs provided to the weldingtorch 14 may be provided to the computer 18. In certain embodiments, thewelding torch 14 may provide inputs to the computer 18 by communicatingdirectly with the computer 18.

The welding torch 14 includes a trigger 70 configured to mechanicallyactuate a trigger switch 72 between an open position (as illustrated)and a closed position. The trigger 70 provides a conductor 71 to carry asignal to the control circuitry 52 to indicate whether the triggerswitch 72 is in the open position or the closed position. The wirefeeder 30, the welding power supply 28, the computer 18, and/or the datareporting device 26 may determine whether there is continuity throughthe welding torch 14 across a first welding conductor 74 and a secondwelding conductor 76. The trigger switch 72 is electrically coupledbetween the first welding conductor 74 and the second welding conductor76. Continuity across the first welding conductor 74 and the secondwelding conductor 76 may be determined by applying a voltage across thewelding conductors 74 and 76, applying a current across the weldingconductors 74 and 76, measuring a resistance across the weldingconductors 74 and 76, and so forth. In certain embodiments, portions ofthe first welding conductor 74 and/or portions of the second weldingconductor 76 may be disposed within a connector of the welding torch 14.Furthermore, in certain embodiments, the arrangement of switches and/orconductors within the welding torch 14 may be different than illustratedin FIG. 2.

The welding power supply 28 may determine whether to enable weldingpower to flow through the welding torch 14 based on whether there iscontinuity across the welding conductors 74 and 76. For example, thewelding power supply 28 may enable welding power to flow through thewelding torch 14 while there is continuity across the welding conductors74 and 76, and the welding power supply 28 may block welding power fromflowing through the welding torch 14 while there is an open circuitacross the welding conductors 74 and 76. Furthermore, the wire feeder 30may provide welding wire to the welding torch 14 while there iscontinuity across the welding conductors 74 and 76, and may blockwelding wire from being provided to the welding torch 14 while there isan open circuit across the welding conductors 74 and 76. Moreover, thecomputer 18 may use the continuity across the welding conductors 74 and76 and/or the position of the trigger 70 or trigger switch 72 to startand/or stop a welding operation, a welding simulation, data recording,and so forth.

With the trigger switch 72 in the open position, there is an opencircuit across the welding conductors 74 and 76, thus, the open positionof the trigger switch 72 blocks electron flow between the weldingconductors 74 and 76. Accordingly, the welding power supply 28 may blockwelding power from flowing through the welding torch 14 and the wirefeeder 30 may block welding wire from being provided to the weldingtorch 14. Pressing the trigger 70 directs the trigger switch 72 to theclosed position where the trigger switch 72 remains as long as thetrigger 70 is pressed. With the trigger switch 72 in the closedposition, there is continuity between the first welding conductor 74 anda conductor 77 electrically connected to the trigger switch 72 and atraining switch 78.

The training switch 78 is electrically coupled between the first weldingconductor 74 and the second welding conductor 76. Moreover, the trainingswitch 78 is electrically controlled by the control circuitry 52 to anopen position or to a closed position. In certain embodiments, thetraining switch 78 may be any suitable electrically controlled switch,such as a transistor, relay, etc. The control circuitry 52 mayselectively control the training switch 78 to the open position or tothe closed position. For example, while welding software of the weldingsystem 10 is operating in a live-arc mode, the control circuitry 52 maybe configured to control the training switch 78 to the closed positionto enable a live welding arc while the trigger 70 is pressed. Incontrast, while welding software of the welding system 10 is operatingin any mode other than the live-arc mode (e.g., simulation, virtualreality, augmented reality, etc.), the control circuitry 52 may beconfigured to control the training switch 78 to the open position toblock a live welding arc (by blocking electron flow between the weldingconductors 74 and 76).

In certain embodiments, the training switch 78 may default to the openposition, thereby establishing an open circuit across the weldingconductors 74 and 76. As may be appreciated, while the training switch78 is in the open position, there will be an open circuit across thewelding conductors 74 and 76 regardless of the position of the triggerswitch 72 (e.g., electron flow between the welding conductors 74 and 76is blocked by the open position of the training switch 78). However,while the training switch 78 is controlled to the closed position, andthe trigger switch 72 is in the closed position, conductivity isestablished between the welding conductors 74 and 76 (e.g., electronflow between the welding conductors 74 and 76 is enabled). Accordingly,the welding power supply 28 may enable welding power to flow through thewelding torch 14 only while the training switch 78 is in the closedposition and while the trigger switch 72 is in the closed position. Forexample, welding power may flow from the welding power supply 28,through a weld cable 80, the welding torch 14, a workpiece 82, andreturn to the welding power supply 28 via a work cable 84 (e.g.,electrode-negative, or straight polarity). Conversely, welding power mayflow from the welding power supply 28, through the work cable 84, theworkpiece 82, the welding torch 14, and return to the welding powersupply 28 via the weld cable 80 (e.g., electrode-positive, or reversepolarity).

As may be appreciated, the training switch 78 may be physically locatedin any suitable portion of the welding system 10, such as the datareporting device 26, the computer 18, and so forth. Furthermore, incertain embodiments, the functionality of the training switch 78 may bereplaced by any suitable hardware and/or software in the welding system10.

FIG. 2A is a schematic diagram of an embodiment of circuitry of thewelding torch 14 of FIG. 1. In the illustrated embodiment, the triggerswitch 72 selectively connects a power supplying conductor (e.g.,voltage source, etc.) to the conductor 71. Accordingly, while thetrigger switch 72 is open, no voltage is applied to the conductor 71,and while the trigger switch 72 is closed, voltage from the powersupplying conductor is supplied to the conductor 71. A trigger enablesignal (e.g., TRIGGER_EN) may be provided by the control circuitry 52 toselectively control the training switch 78, and thereby control a feederenable switch 85. For example, when the trigger enable signal controlsthe training switch 78 to an open position, no voltage is applied to thefeeder enable switch 85 (e.g., via the FEEDER_EN connection), therebymaintaining the feeder enable switch 85 in the open position.Conversely, when the trigger enable signal controls the training switch78 to a closed position, voltage is applied to the feeder enable switch85, thereby controlling the feeder enable switch 85 to the closedposition. With the feeder enable switch 85 in the closed position,conductivity between the welding conductors 74 and 76 is established.While one example of welding torch 14 circuitry is provided, anysuitable circuitry may be used within the welding torch 14. Amicroprocessor of the control circuitry 52 may pulse the trigger enablesignal at predetermined intervals to provide an indication to detectioncircuitry of the control circuitry 52 that the trigger enable signal isworking properly. If the detection circuitry does not detect the triggerenable signal, the trigger may not be enabled.

FIG. 3 is a perspective view of an embodiment of the welding torch 14 ofFIGS. 1 and 2. As illustrated, the user interface 60 includes multiplebuttons 86 which may be used to provide inputs to the welding torch 14.For example, the buttons 86 may enable a welding operator to navigatethrough welding software. Furthermore, the welding torch 14 includes thedisplay 62 which may show the welding operator data corresponding to thewelding software, data corresponding to a welding operation, and soforth. As illustrated, the LEDs 64 may be positioned at variouslocations on the welding torch 14. Accordingly, the LEDs 64 may beilluminated to facilitate detection by the sensing device 16.

FIG. 4 is a perspective view of an embodiment of the stand 12 of FIG. 1.The stand 12 includes a welding surface 88 on which live welds (e.g.,real welds, actual welds) and/or simulated welds may be performed. Legs90 provide support to the welding surface 88. In certain embodiments,the welding surface 88 may include slots 91 to aid a welding operator inpositioning and orienting the workpiece 82. In certain embodiments, theposition and orientation of the workpiece 82 may be provided to weldingsoftware of the welding system 10 to calibrate the welding system 10.For example, a welding operator may provide an indication to the weldingsoftware identifying which slot 91 of the welding surface 88 theworkpiece 82 is aligned with. Furthermore, a predefined weldingassignment may direct the welding operator to align the workpiece 82with a particular slot 91. In certain embodiments, the workpiece 82 mayinclude an extension 92 configured to extend into one or more of theslots 91 for alignment of the workpiece 82 with the one or more slots91. As may be appreciated, each of the slots 91 may be positioned at alocation corresponding to a respective location defined in the weldingsoftware.

The welding surface 88 includes a first aperture 93 and a secondaperture 94. The first and second apertures 93 and 94 may be usedtogether to determine a position and/or an orientation of the weldingsurface 88. As may be appreciated, in certain embodiments at least threeapertures may be used to determine the position and/or the orientationof the welding surface 88. In some embodiments, more than threeapertures may be used to determine the position and/or the orientationof the welding surface 88. The first and second apertures 93 and 94 maybe positioned at any suitable location on the welding surface 88, andmay be any suitable size. In certain embodiments, the position and/ororientation of the welding surface 88 relative to the sensing device 16may be calibrated using the first and second apertures 93 and 94. Forexample, as described in greater detail below, a calibration deviceconfigured to be sensed by the sensing device 16 may be inserted intothe first aperture 93, or touched to the first aperture 93. While thecalibration device is inserted into, or touching, the first aperture 93,a user input provided to the welding software (or other calibrationsoftware) may indicate that the calibration device is inserted into thefirst aperture 93. As a result, the welding software may establish acorrelation between a first data set (e.g., calibration data) receivedfrom the sensing device 16 (e.g., position and/or orientation data) at afirst time and the location of first aperture 93. The calibration devicemay next be inserted into the second aperture 94, or touched to thesecond aperture 94. While the calibration device is inserted into, ortouching, the second aperture 94, a user input provided to the weldingsoftware may indicate that the calibration device is inserted into thesecond aperture 94. As a result, the welding software may establish acorrelation between a second data set (e.g., calibration data) receivedfrom the sensing device 16 at a second time and the location of secondaperture 94. Thus, the welding software may be able to calibrate theposition and/or orientation of the welding surface 88 relative to thesensing device 16 using the first data set received at the first timeand the second data set received at the second time.

The welding surface 88 also includes a first marker 95 and a secondmarker 96. The first and second markers 95 and 96 may be used togetherto determine a position and/or an orientation of the welding surface 88.As may be appreciated, in certain embodiments at least three markers maybe used to determine the position and/or the orientation of the weldingsurface 88. In some embodiments, more than three markers may be used todetermine the position and/or the orientation of the welding surface 88.The first and second markers 95 and 96 may be formed from any suitablematerial. Moreover, in certain embodiments, the first and second markers95 and 96 may be built into the welding surface 88, while in otherembodiments, the first and second markers 95 and 96 may be attached tothe welding surface 88. For example, the first and second markers 95 and96 may be attached to the welding surface 88 using an adhesive and/orthe first and second markers 95 and 96 may be stickers. The first andsecond markers 95 and 96 may have any suitable shape, size, and/orcolor. Furthermore, in certain embodiments, the first and second markers95 and 96 may be a reflector formed from a reflective material. Thefirst and second markers 95 and 96 may be used by the welding system 10to calibrate the position and/or orientation of the welding surface 88relative to the sensing device 16 without a separate calibration device.Accordingly, the first and second markers 95 and 96 are configured to bedetected by the sensing device 16. In certain embodiments, the first andsecond markers 95 and 96 may be positioned at predetermined locations onthe welding surface 88. Furthermore, the welding software may beprogrammed to use the predetermined locations to determine the positionand/or the orientation of the welding surface 88. In other embodiments,the location of the first and second markers 95 and 96 may be providedto the welding software during calibration. With the first and secondmarkers 95 and 96 on the welding surface 88, the sensing device 16 maysense the position and/or orientation of the first and second markers 95and 96 relative to the sensing device 16. Using this sensed data inconjunction with the location of the first and second markers 95 and 96on the welding surface 88, the welding software may be able to calibratethe position and/or orientation of the welding surface 88 relative tothe sensing device 16. In some embodiments, the welding surface 88 maybe removable and/or reversible. In such embodiments, the welding surface88 may be flipped over, such as if the welding surface 88 become worn.

In the illustrated embodiment, the workpiece 82 includes a first marker98 and a second marker 99. The first and second markers 98 and 99 may beused together to determine a position and/or an orientation of theworkpiece 82. As may be appreciated, at least two markers are used todetermine the position and/or the orientation of the workpiece 82. Incertain embodiments, more than two markers may be used to determine theposition and/or the orientation of the workpiece 82. The first andsecond markers 98 and 99 may be formed from any suitable material.Moreover, in certain embodiments, the first and second markers 98 and 99may be built into the workpiece 82, while in other embodiments, thefirst and second markers 98 and 99 may be attached to the workpiece 82.For example, the first and second markers 98 and 99 may be attached tothe workpiece 82 using an adhesive and/or the first and second markers98 and 99 may be stickers. As a further example, the first and secondmarkers 98 and 99 may be clipped or clamped onto the workpiece 82. Thefirst and second markers 98 and 99 may have any suitable shape, size,and/or color. Furthermore, in certain embodiments, the first and secondmarkers 98 and 99 may be a reflector formed from a reflective material.The first and second markers 98 and 99 may be used by the welding system10 to calibrate the position and/or orientation of the workpiece 82relative to the sensing device 16 without a separate calibration device.Accordingly, the first and second markers 98 and 99 are configured to bedetected by the sensing device 16. In certain embodiments, the first andsecond markers 98 and 99 may be positioned at predetermined locations onthe workpiece 82. Furthermore, the welding software may be programmed touse the predetermined locations to determine the position and/or theorientation of the workpiece 82. In other embodiments, the location ofthe first and second markers 98 and 99 may be provided to the weldingsoftware during calibration. With the first and second markers 98 and 99on the workpiece 82, the sensing device 16 may sense the position and/ororientation of the first and second markers 98 and 99 relative to thesensing device 16. Using this sensed data in conjunction with thelocation of the first and second markers 98 and 99 on the workpiece 82,the welding software may be able to calibrate the position and/ororientation of the workpiece 82 relative to the sensing device 16. Whilethe markers 95, 96, 98, and 99 have been described herein as beingdetected by the sensing device 16, in certain embodiments, the markers95, 96, 98, and 99 may indicate locations where a calibration device isto be touched for calibration using the calibration device, as describedpreviously.

The stand 12 includes a first arm 100 extending vertically from thewelding surface 88 and configured to provide support for the sensingdevice 16 and the display 32. A knob 101 is attached to the first arm100 and may be used to adjust an orientation of the sensing device 16relative to the first arm 100. For example, as the knob 101 is adjusted,mechanical components extending through the first arm 100 may adjust anangle of the sensing device 16. The display 32 includes a cover 102 toprotect the display 32 from welding emissions that may occur during alive welding operation. The cover 102 may be made from any suitablematerial, such as a transparent material, a polymer, and so forth. Byusing a transparent material, a welding operator may view the display 32while the cover 102 is positioned in front of the display 32, such asbefore, during, and/or after a welding operation. A camera 104 may becoupled to the first arm 100 for recording welding operations. Incertain embodiments, the camera 104 may be a high dynamic range (HDR)camera. Furthermore, an emitter 105 may be coupled to the first arm 100.The emitter 105 may be used to calibrate the position and/or orientationof the welding surface 88 relative to the sensing device 16. Forexample, the emitter 105 may be configured to emit a visible patternonto the welding surface 88. The visible pattern may be shown onto thewelding surface 88. Furthermore, the visible pattern may be detected bythe sensing device 16 to calibrate the position and/or the orientationof the welding surface 88 relative to the sensing device 16. Forexample, based on particular features of the visible pattern alignmentsand/or orientations may be determined by the sensing device 16 and/orthe welding software. Moreover, the visible pattern emitted by theemitter 105 may be used to facilitate positioning of the workpiece 82 onthe welding surface 88.

The stand 12 also includes a second arm 106 extending vertically fromthe welding surface 88 and configured to provide support for a weldingplate 108 (e.g., vertical welding plate, horizontal welding plate,overhead welding plate, etc.). The second arm 106 may be adjustable tofacilitate overhead welding at different heights. Moreover, the secondarm 106 may be manufactured in a number of different ways to facilitateoverhead welding at different heights. The welding plate 108 is coupledto the second arm 106 using a mounting assembly 110. The mountingassembly 110 facilitates rotation of the welding plate 108 asillustrated by arrow 111. For example, the welding plate 108 may berotated from extending generally in the horizontal plane (e.g., foroverhead welding), as illustrated, to extend generally in the verticalplane (e.g., for vertical welding). The welding plate 108 includes awelding surface 112. The welding surface 112 includes slots 114 that mayaid a welding operator in positioning the workpiece 82 on the weldingsurface 112, similar to the slots 91 on the welding surface 88. Incertain embodiments, the position of the workpiece 82 may be provided towelding software of the welding system 10 to calibrate the weldingsystem 10. For example, a welding operator may provide an indication tothe welding software identifying which slot 114 of the welding surface112 the workpiece 82 is aligned with. Furthermore, a predefined weldingassignment may direct the welding operator to align the workpiece 82with a particular slot 114. In certain embodiments, the workpiece 82 mayinclude an extension configured to extend into one or more of the slots114 for alignment of the workpiece 82 with the one or more slots 114. Asmay be appreciated, each of the slots 114 may be positioned at alocation corresponding to a respective location defined in the weldingsoftware.

The welding surface 112 also includes a first marker 116 and a secondmarker 118. The first and second markers 116 and 118 may be usedtogether to determine a position and/or an orientation of the weldingsurface 112. As may be appreciated, at least two markers are used todetermine the position and/or the orientation of the welding surface112. In certain embodiments, more than two markers may be used todetermine the position and/or the orientation of the welding surface112. The first and second markers 116 and 118 may be formed from anysuitable material. Moreover, in certain embodiments, the first andsecond markers 116 and 118 may be built into the welding surface 112 (oranother part of the welding plate 108), while in other embodiments, thefirst and second markers 116 and 118 may be attached to the weldingsurface 112 (or another part of the welding plate 108). For example, thefirst and second markers 116 and 118 may be attached to the weldingsurface 112 using an adhesive and/or the first and second markers 116and 118 may be stickers. As a further example, the first and secondmarkers 116 and 118 may be clipped or clamped onto the welding surface112. In some embodiments, the first and second markers 116 and 118 maybe integrated into a holding clamp that is clamped onto a weldingcoupon. The first and second markers 116 and 118 may have any suitableshape, size, and/or color. Furthermore, in certain embodiments, thefirst and second markers 116 and 118 may be a reflector formed from areflective material.

The first and second markers 116 and 118 may be used by the weldingsystem 10 to calibrate the position and/or orientation of the weldingsurface 112 relative to the sensing device 16 without a separatecalibration device. Accordingly, the first and second markers 116 and118 are configured to be detected by the sensing device 16. In certainembodiments, the first and second markers 116 and 118 may be positionedat predetermined locations on the welding surface 112. Furthermore, thewelding software may be programmed to use the predetermined locations todetermine the position and/or the orientation of the welding surface112. In other embodiments, the location of the first and second markers116 and 118 may be provided to the welding software during calibration.With the first and second markers 116 and 118 on the welding surface112, the sensing device 16 may sense the position and/or orientation ofthe first and second markers 116 and 118 relative to the sensing device16. Using this sensed data in conjunction with the location of the firstand second markers 116 and 118 on the welding surface 112, the weldingsoftware may be able to calibrate the position and/or orientation of thewelding surface 112 relative to the sensing device 16. Furthermore, thesensing device 16 may sense and/or track the first and second markers116 and 118 during a weld to account for any movement of the weldingplate 108 that may occur during the weld. While the markers 116 and 118have been described herein as being detected by the sensing device 16,in certain embodiments, the markers 116 and 118 may indicate locationswhere a calibration device is to be touched or inserted for calibrationusing the calibration device, as described previously.

FIG. 5 is a perspective view of an embodiment of a calibration device120. In some embodiments, the calibration device 120 is shaped like atorch and may be used for calibrating the position and/or orientation ofthe welding surfaces 88 and 112 relative to the sensing device 16. Inother embodiments, the calibration device 120 may be used forcalibrating the position and/or orientation of a welding joint. Thecalibration device 120 includes a handle 122 and a nozzle 124. Thenozzle 124 includes a pointed end 126 that may be used to touch alocation for calibration and/or to be inserted into an aperture forcalibration. The calibration device 120 also includes a user interface128 that enables the welding operator to provide input corresponding toa time that the calibration device 120 is touching a location forcalibration and/or is being inserted into an aperture for calibration.Moreover, in certain embodiments, the calibration device 120 includesmarkers 130 configured to be sensed by the sensing device 16. Asillustrate, the markers 130 extend from the calibration device 120.However, in other embodiments, the markers 130 may not extend from thecalibration device 120. The markers 130 may be any suitable markerconfigured to be detected by the sensing device 16. Moreover, themarkers 130 may be any suitable size, shape, and/or color.

During calibration, the sensing device 16 may sense a position of thecalibration device 120 and/or an orientation of the calibration device120. The position and/or orientation of the calibration device 120 maybe used by the welding software to determine a position and/ororientation of one or more of the welding surfaces 88 and 112 relativeto the sensing device 16, a position and/or orientation of the workpiece82 relative to the sensing device 16, a position and/or orientation of afixture relative to the sensing device 16, and so forth. Thus, thecalibration device 120 may facilitate calibration of the welding system10. In some embodiments, a tray may be positioned beneath the weldingsurface 88 for storing the calibration device 120. Moreover, in certainembodiments live welding may be disabled if the calibration device 120is able to be tracked by the sensing device 16 (e.g., to block spatterfrom contacting the calibration device 120).

FIG. 6 is a perspective view of an embodiment of a fixture assembly 132.The fixture assembly 132 may be positioned on the welding surface 88and/or the welding surface 112, and may secure the workpiece 82 thereon.In certain embodiments, the fixture assembly 132 may be configured toalign with one or more of the slots 92 and 114. In other embodiments,the fixture assembly 132 may be placed at any location on the weldingsurface 88 and/or the welding surface 122. The fixture assembly 132 alsoincludes a first marker 134 and a second marker 136. The first andsecond markers 134 and 136 may be used together to determine a positionand/or an orientation of the fixture assembly 132. As may beappreciated, at least two markers are used to determine the positionand/or the orientation of the fixture assembly 132. The first and secondmarkers 134 and 136 may be formed from any suitable material. Moreover,in certain embodiments, the first and second markers 134 and 136 may bebuilt into the fixture assembly 132, while in other embodiments, thefirst and second markers 134 and 136 may be attached to the fixtureassembly 132. For example, the first and second markers 134 and 136 maybe attached to the fixture assembly 132 using an adhesive and/or thefirst and second markers 134 and 136 may be stickers. The first andsecond markers 134 and 136 may have any suitable shape, size, and/orcolor. Furthermore, in certain embodiments, the first and second markers134 and 136 may be a reflector formed from a reflective material. Thefirst and second markers 134 and 136 may be used by the welding system10 to calibrate the position and/or orientation of the fixture assembly132 relative to the sensing device 16 without a separate calibrationdevice. Accordingly, the first and second markers 134 and 136 areconfigured to be detected by the sensing device 16. In certainembodiments, the first and second markers 134 and 136 may be positionedat predetermined locations on the fixture assembly 132. Furthermore, thewelding software may be programmed to use the predetermined locations todetermine the position and/or the orientation of the fixture assembly132. In other embodiments, the location of the first and second markers134 and 136 may be provided to the welding software during calibration.With the first and second markers 134 and 136 on the fixture assembly132, the sensing device 16 may sense the position and/or orientation ofthe first and second markers 134 and 136 relative to the sensing device16. Using this sensed data in conjunction with the location of the firstand second markers 134 and 136 on the fixture assembly 132, the weldingsoftware may be able to calibrate the position and/or orientation of thefixture assembly 132 relative to the sensing device 16. While the firstand second markers 134 and 136 have been described herein as beingdetected by the sensing device 16, in certain embodiments, the first andsecond markers 134 and 136 may indicate locations where a calibrationdevice is to be touched or inserted for calibration using thecalibration device 120, as described previously.

In the illustrated embodiment, the fixture assembly 132 is configured tosecure a lower portion 138 of the workpiece 82 to an upper portion 140of the workpiece 82 for performing a lap weld. In other embodiments, thefixture assembly 132 may be configured to secure portions of theworkpiece 82 for performing a butt weld, a fillet weld, and so forth, toaid a welding operator in performing a weld. The fixture assembly 132includes vertical arms 142 extending from a base 143. A cross bar 144extends between the vertical arms 142, and is secured to the verticalarms 142. Adjustment mechanisms 146 (e.g., knobs) may be adjusted todirect locking devices 148 toward the workpiece 82 for securing theworkpiece 82 between the locking devices 148 and the base 143 of thefixture assembly 132. Conversely, the adjustment mechanisms 146 may beadjusted to direct the locking devices 148 away from the workpiece 82for removing the workpiece 82 from being between the locking devices 148and the base 143. Accordingly, the workpiece 82 may be selectivelysecured to the fixture assembly 132.

FIG. 7 is a perspective view of a welding wire stickout calibration tool150. The tool 150 is configured to calibrate a length of welding wireextending out of a torch nozzle to a selectable length. Accordingly, thetool 150 includes a first handle 152 and a second handle 154. The tool150 also includes a torch nozzle holder 156 attached to a centralportion 157 of the tool 150 and extending outward from the centralportion 157 a selected distance. In the illustrated embodiment, thetorch nozzle holder 156 has a generally cylindrical body 158 (e.g., cupshape); however, in other embodiments, the body 158 of the torch nozzleholder 156 may have any suitable shape. Moreover, the torch nozzleholder 156 is configured to receive the torch nozzle through a nozzleinlet 160 such that the torch nozzle extends into the body 158.Furthermore, the torch nozzle holder 156 includes an opening 162configured to enable welding wire to extend out the end of the torchnozzle holder 156, and to block the torch nozzle from extending throughthe opening 162. As the torch nozzle extends into the torch nozzleholder 156, the welding wire extends out of the opening 162 of the torchnozzle holder 156 toward a blade assembly 164 of the tool 150. The bladeassembly 164 includes one or more sides 165 and 166 configured tocontact the welding wire. In certain embodiments, both of sides 165 and166 include blades to cut opposing sides of the welding wire, while inother embodiments, only one of the sides 165 and 166 includes a blade tocut one side of the welding wire and the other side includes a surfaceto which the blade is directed toward. For calibrating the length of thewelding wire, the welding wire may extend through the opening 162 andinto the blade assembly 164. The welding wire may be cut to a selectablelength by pressing the first handle 152 and the second handle 154 towardone another, thereby calibrating the length of wire extending from thetorch nozzle. The calibration length may be selected using an adjustmentmechanism 167 to adjust a distance 168 between the blade assembly 164and the opening 162 of the torch nozzle holder 156. Thus, using the tool150, the length of wire extending from the torch nozzle may becalibrated.

FIG. 8 is a top view of the welding wire stickout calibration tool 150of FIG. 7. As illustrated, the welding torch 14 may be used with thetool 150. Specifically, a nozzle 170 of the welding torch 14 may beinserted into the torch nozzle holder 156 in a direction 172. Weldingwire 174 extending from the welding torch 14 is directed through thenozzle inlet 160, the opening 162, and the blade assembly 164.Accordingly, the first and second handles 152 and 154 may be pressedtogether to cut the welding wire 174 to the distance 168 (e.g., thecalibration length) set by the adjustment mechanism 167.

FIG. 9 is an embodiment of a method 176 for calibrating wire stickoutfrom the welding torch 14. The tool 150 may be used to calibrate thelength of welding wire 174 extending from the nozzle 170 using a varietyof methods. In the method 176, the adjustment mechanism 167 of thewelding wire stickout calibration tool 150 may be adjusted for aselected welding wire 174 length (block 178). For example, the distance168 of the torch nozzle holder 156 from the tool 150 may be set to arange of between approximately 0.5 to 2.0 cm, 1.0 to 3.0 cm, and soforth. The welding torch 14 may be inserted into the torch nozzle holder156 of the tool 150, such that the nozzle 170 of the welding torch 14abuts the torch nozzle holder 156, and that the welding wire 174 extendsthrough the opening 162 of the torch nozzle holder 156 (block 180). Incertain embodiments, the welding wire 174 may be long enough to extendthrough the blade assembly 164. However, if the welding wire 174 doesnot extend through the blade assembly 164, a welding operator mayactuate the trigger 70 of the welding torch 14 to feed welding wire 174such that the welding wire 174 extends through the blade assembly 164(block 182). Accordingly, the welding operator may compress handles 152and 154 of the tool 150 to cut the welding wire 174 extending throughthe blade assembly 164 and thereby calibrate the length of the weldingwire 174 (block 184).

FIG. 10 is a perspective view of an embodiment of a welding consumable186 having physical marks. The welding consumable 186 may be anysuitable welding consumable, such as a welding stick, welding rod, or awelding electrode. The welding consumable 186 includes physical marks188, 190, 192, 194, 196, 198, 200, 202, and 204. The physical marks 188,190, 192, 194, 196, 198, 200, 202, and 204 may be any suitable physicalmark. For example, the physical marks 188, 190, 192, 194, 196, 198, 200,202, and 204 may include a bar code, an image, a shape, a color, text, aset of data, and so forth. In certain embodiments, the physical marks188, 190, 192, 194, 196, 198, 200, 202, and 204 may be laser etched.Furthermore, in certain embodiments, the physical marks 188, 190, 192,194, 196, 198, 200, 202, and 204 may be visible with the natural eye(e.g., within the visible spectrum), while in other embodiments thephysical marks 188, 190, 192, 194, 196, 198, 200, 202, and 204 may notbe visible with the natural eye (e.g., not within the visible spectrum).

Each of the physical marks 188, 190, 192, 194, 196, 198, 200, 202, and204 indicates a location on the welding consumable 186 relative toeither a first end 206, or a second end 208 of the welding consumable186. For example, the physical mark 188 may indicate a distance from thefirst end 206, a distance from the second end 208, or some otherlocation relative to the welding consumable 186. In certain embodiments,the physical marks 188, 190, 192, 194, 196, 198, 200, 202, and 204 mayindicate a number that corresponds to the first end 206 and/or thesecond end 208. For example, the physical mark 188 may indicate a number“1” indicating that it is the first physical mark from the first end 206and/or the physical mark 188 may indicate a number “9” indicating thatit is the ninth physical mark from the second end 208. A processingdevice may use a lookup table to determine a distance from the first end206 or the second end 208 based on the number indicated by the physicalmark.

A camera-based detection system, which may include the sensing device16, or another type of system is configured to detect the physical marks188, 190, 192, 194, 196, 198, 200, 202, and 204 during live arc weldingor a welding simulation. Moreover, the camera-based detection system isconfigured to determine a remaining length of the welding consumable186, a consumed length of the welding consumable 186, a rate of use ofthe welding consumable 186, a dipping rate of the welding consumable186, and so forth, based on the detected physical marks. Accordingly,data corresponding to use of the welding consumable 186 may be trackedby the welding system 10 for training and/or analysis.

FIG. 11 is a perspective view of an embodiment of welding wire 210having physical marks 212, 214, 216, and 218. The physical marks 212,214, 216, and 218 may be any suitable physical mark. For example, thephysical marks 212, 214, 216, and 218 may include a bar code, an image,a shape, text, a set of data, and so forth. In certain embodiments, thephysical marks 212, 214, 216, and 218 may be laser etched. Furthermore,in certain embodiments, the physical marks 212, 214, 216, and 218 may bevisible with the natural eye (e.g., within the visible spectrum), whilein other embodiments the physical marks 212, 214, 216, and 218 may notbe visible with the natural eye (e.g., not within the visible spectrum).

Each of the physical marks 212, 214, 216, and 218 indicates a locationon the welding wire 210 relative to either a first end 220, or a secondend 222 of the welding wire 210. For example, the physical mark 212 mayindicate a distance from the first end 220, a distance from the secondend 222, or some other location relative to the welding wire 210. Incertain embodiments, the physical marks 212, 214, 216, and 218 mayindicate a number that corresponds to the first end 220 and/or thesecond end 222. For example, the physical mark 212 may indicate a number“1” indicating that it is the first physical mark from the first end 220and/or the physical mark 212 may indicate a number “4” indicating thatit is the fourth physical mark from the second end 222. A processingdevice may use a lookup table to determine a distance from the first end220 or the second end 222 based on the number indicated by the physicalmark.

A camera-based detection system, which may include the sensing device16, or another type of system is configured to detect the physical marks212, 214, 216, and 218 during live arc welding or a welding simulation.Moreover, the camera-based detection system is configured to determine aremaining length of the welding wire 210, a consumed length of thewelding wire 210, a rate of use of the welding wire 210, a dipping rateof the welding wire 210, and so forth, based on the detected physicalmarks. Accordingly, data corresponding to use of the welding wire 210may be tracked by the welding system 10 for training and/or analysis.

FIG. 12 is a perspective view of an embodiment of a vertical armassembly 223 of the stand 12 of FIG. 4. As illustrated, the sensingdevice 16 is attached to the first arm 100. Furthermore, the sensingdevice 16 includes cameras 224, and an infrared emitter 226. However, inother embodiments, the sensing device 16 may include any suitable numberof cameras, emitters, and/or other sensing devices. A pivot assembly 228is coupled to the first arm 100 and to the sensing device 16, andenables an angle of the sensing device 16 to be adjusted while thesensing device 16 rotates as illustrated by arrow 229. As may beappreciated, adjusting the angle of the sensing device 16 relative tothe first arm 100 changes the field of view of the sensing device 16(e.g., to change the portion of the welding surface 88 and/or thewelding surface 112 sensed by the sensing device 16).

A cord 230 extends between the knob 101 and the sensing device 16. Thecord 230 is routed through a pulley 232 to facilitate rotation of thesensing device 16. Thus, a welding operator may rotate the knob 101 tomanually adjust the angle of the sensing device 16. As may beappreciated, the combination of the cord 230 and the pulley 232 is oneexample of a system for rotating the sensing device 16. It should benoted that any suitable system may be used to facilitate rotation of thesensing device 16. While one embodiment of a knob 101 is illustrated, itmay be appreciated that any suitable knob may be used to adjust theangle of the sensing device 16. Furthermore, the angle of the sensingdevice 16 may be adjusted using a motor 234 coupled to the cord 230.Accordingly, a welding operator may operate the motor 234 to adjust theangle of the sensing device 16. Moreover, in certain embodiments,control circuitry may be coupled to the motor 234 and may control theangle of the sensing device 16 based on a desired field of view of thesensing device 16 and/or based on tracking of an object within the fieldof view of the sensing device 16.

FIG. 13 is a perspective view of an embodiment of an overhead weldingarm assembly 235. The overhead welding arm assembly 235 illustrates oneembodiment of a manufacturing design that enables the second arm 106 tohave an adjustable height. Accordingly, as may be appreciated, thesecond arm 106 may be manufactured to have an adjustable height in anumber of ways. As illustrated, the overhead welding assembly 235includes handles 236 used to vertically raise and/or lower the secondarm 106 as illustrated by arrows 238. The overhead welding arm assembly235 includes a locking device 240 to lock the second arm 106 at adesired height. For example, the locking device 240 may include a buttonthat is pressed to disengage a latch configured to extend into openings242, thus unlocking the second arm 106 from being secured to side rails243. With the second arm 106 unlocked from the side rails 243, thehandles 236 may be vertically adjusted to a desired height, therebyadjusting the plate 112 to a desired height. As may be appreciated,releasing the button may result in the latch extending into the openings242 and locking the second arm 106 to the side rails 243. As may beappreciated, the locking device 240 may operate manually as describedand/or the locking device 240 may be controlled by a control system(e.g., automatically controlled). Furthermore, the second arm 106 may bevertically raised and/or lowered using the control system. For example,in certain embodiments, the welding software may control the second arm106 to move to a desired position automatically. Thus, the plate 112 maybe adjusted to a desired height for overhead welding.

FIG. 14 is a block diagram of an embodiment of welding software 244(e.g., welding training software) of the welding system 10 havingmultiple modes. As illustrated, the welding software 244 may include oneor more of a live-arc mode 246 configured to enable training using alive (e.g., actual) welding arc, a simulation mode 248 configured toenable training using a welding simulation, a virtual reality (VR) mode250 configured to enable training using a VR simulation, and/or anaugmented reality mode 252 configured to enable training using augmentedreality simulation.

The welding software 244 may receive signals from an audio input 254.The audio input 254 may be configured to enable a welding operator tooperate the welding software 244 using audible commands (e.g., voiceactivation). Furthermore, the welding software 244 may be configured toprovide an audio output 256 and/or a video output 258. For example, thewelding software 244 may provide audible information to a weldingoperator using the audio output 256. Such audible information mayinclude instructions for configuring (e.g., setting up) the weldingsystem 10, real-time feedback provided to a welding operator during awelding operation, instructions to a welding operator before performinga welding operation, instructions to a welding operator after performinga welding operation, warnings, and so forth.

FIG. 15 is a block diagram of an embodiment of the VR mode 250 of thewelding software 244. The VR mode 250 is configured to provide a weldingoperator with a VR simulation 260. The VR simulation 260 may bedisplayed to a welding operator through a VR headset, VR glasses, a VRdisplay, or any suitable VR device. The VR simulation 260 may beconfigured to include a variety of virtual objects, such as the objectsillustrated in FIG. 15, that enable interaction between a weldingoperator and a selected virtual object of the variety of virtual objectswithin the VR simulation 260. For example, virtual objects may include avirtual workpiece 262, a virtual welding stand 264, a virtual weldingtorch 266, virtual wire cutters 268, virtual software configuration 270,virtual training data results 272, and/or a virtual glove 274.

In certain embodiments, the welding operator may interact with thevirtual objects without touching a physical object. For example, thesensing device 16 may detect movement of the welding operator and mayresult in similar movements occurring in the VR simulation 260 based onthe welder operator's movements in the real world. In other embodiments,the welding operator may use a glove or the welding torch 14 to interactwith the virtual objects. For example, the glove or the welding torch 14may be detected by the sensing device 16, and/or the glove or thewelding torch 14 may correspond to a virtual object in the VR simulation260. Furthermore, the welding operator may be able to operate thewelding software 244 within the VR simulation 260 using the virtualsoftware configuration 270 and/or the virtual training data results 272.For example, the welding operator may use their hand, the glove, or thewelding torch 14 to select items within the welding software 244 thatare displayed virtually within the VR simulation 260. Moreover, thewelding operator may perform other actions such as picking up wirecutters and cutting virtual welding wire extending from the virtualtorch 266, all within the VR simulation 260.

FIG. 16 is an embodiment of a method 276 for integrating trainingresults data. The method 276 includes the welding software 244 of thecomputer 18 receiving a first set of welding data from a storage device(e.g., storage device 24) (block 278). The first set of welding data mayinclude welding data corresponding to a first welding assignment. Themethod 276 also includes the welding software 244 receiving a second setof welding data from the storage device (block 280). In certainembodiments, the first set and/or second set of welding data may bereceived from a network storage device. The network storage device maybe configured to receive welding data from and/or to provide weldingdata to the welding system 10 and/or the external welding system 40. Thewelding software 244 may integrate the first and second sets of weldingdata into a chart to enable a visual comparison of the first set ofwelding data with the second set of welding data (block 282). As may beappreciated, the chart may be a bar chart, a pie chart, a line chart, ahistogram, and so forth. In certain embodiments, integrating the firstset of welding data with the second set of welding data includesfiltering the first set of welding data and the second set of weldingdata to display a subset of the first set of welding data and a subsetof the second set of welding data. The welding software 244 may providethe chart to a display device (e.g., the display 32) (block 284). Incertain embodiments, providing the chart to the display device includesproviding selectable elements on the chart that when selected displaydata corresponding to a respective selected element of the selectableelements (e.g., selecting wire speed from the chart may change thescreen to display the wire speed history for a particular weldingassignment).

The first set of welding data and/or the second set of welding data mayinclude a welding torch orientation, a welding torch travel speed, awelding torch position, a contact tip to workpiece distance, a proximityof the welding torch in relation to the workpiece, an aim of the weldingtorch, a welding score, a welding grade, and so forth. Moreover, thefirst set of welding data and the second set of welding data maycorrespond to training performed by one welding operator and/or by aclass of welding operators. Furthermore, the first welding assignmentand the second welding assignment may correspond to training performedby one welding operator and/or by a class of welding operators. Incertain embodiments, the first welding assignment may correspond totraining performed by a first welding operator, and the second weldingassignment may correspond to welding performed by a second weldingoperator. Moreover, the first assignment and the second assignment maycorrespond to the same welding scenario.

FIG. 17 is an embodiment of a chart 285 illustrating multiple sets ofwelding data for a welding operator. The chart 285 may be produced bythe welding software 244 and may be provided to the display 32 to beused by a welding instructor to review welding operations performed by awelding student, and/or may be provided to the display 32 to be used bya welding student to review welding operations performed by that weldingstudent. The chart 285 illustrates a bar graph comparison betweendifferent assignments of a first set of welding assignments performed bya welding operator. The first set of welding assignments includesassignments 286, 288, 290, 292, and 294. The chart 285 also illustratesa bar graph comparison between different assignments of a second set ofwelding assignments performed by the welding operator. The second set ofwelding assignments includes assignments 296, 298, 300, 302, and 304.Accordingly, welding assignments may be compared to one another foranalysis, instruction, certification, and/or training purposes. Asillustrated, the welding assignments may be compared to one anotherusing one of any number of criteria, such as a total score, a workangle, a travel angle, a travel speed, a contact to work distance, aproximity, a mode (e.g., live-arc mode, simulation mode, etc.), acompletion status (e.g., complete, incomplete, partially complete,etc.), a joint type (e.g., fillet, butt, T, lap, etc.), a weldingposition (e.g., flat, vertical, overhead, etc.), a type of metal used, atype of filler metal, and so forth.

FIG. 18 is an embodiment of a chart 305 illustrating welding data for awelder compared to welding data for a class. For example, the chart 305illustrates a score 306 of a welding operator compared to a score 308(e.g., average, median, or some other score) of a class for a firstassignment. Furthermore, a score 310 of the welding operator is comparedto a score 312 (e.g., average, median, or some other score) of the classfor a second assignment. Moreover, a score 314 of the welding operatoris compared to a score 316 (e.g., average, median, or some other score)of the class for a third assignment. As may be appreciated, scores fromone or more welding operators may be compared to scores of the entireclass. Such a comparison enables a welding instructor to assess theprogress of individual welding students as compared to the class ofwelding students. Furthermore, scores from one or more welding operatorsmay be compared to scores of one or more other welding operators. Incertain embodiments, scores from one class may be compared to scores ofanother class. Moreover, scores from the first assignment, the secondassignment, and/or the third assignment may be selected for comparison.

FIG. 19 is a block diagram of an embodiment of a data storage system 318for storing certification status data. The certification status data maybe produced as a welding operator completes various assignments in thewelding system 10. For example, a predetermined set of assignments maycertify a welding operator for a particular welding device and/orwelding process. The data storage system 318 includes control circuitry320, one or more memory devices 322, and one or more storage devices324. The control circuitry 320 may include one or more processors, whichmay be similar to the processor(s) 20. Furthermore, the memory device(s)322 may be similar to the memory device(s) 22, and the storage device(s)324 may be similar to the storage device(s) 24. The memory device(s) 322and/or the storage device(s) 324 may be configured to storecertification status data 326 corresponding to a welding certification(e.g., welding training certification) of a welding operator.

The certification status data 326 may include welding data of thewelding operator (e.g., any data that is related to the assignments tocertify the welding operator), any data related to an actualcertification (e.g., certified, not certified, qualified, not qualified,etc.), a quantity of one or more welds performed by the weldingoperator, a timestamp for one or more welds performed by the weldingoperator, welding parameter data for one or more welds performed by thewelding operator, a quality ranking of the welding operator, a qualitylevel of the welding operator, a history of welds performed by thewelding operator, a history of production welds performed by the weldingoperator, a first welding process (e.g., a metal inert gas (MIG) weldingprocess, a tungsten inert gas (TIG) welding process, a stick weldingprocess, etc.) certification status (e.g., the welding operator iscertified for the first welding process, the welding operator is notcertified for the first welding process), a second welding processcertification status (e.g., the welding operator is certified for thesecond welding process, the welding operator is not certified for thesecond welding process), a first welding device (e.g., a wire feeder, apower supply, a model number, etc.) certification status (e.g., thewelding operator is certified for the first welding device, the weldingoperator is not certified for the first welding device), and/or a secondwelding device certification status (e.g., the welding operator iscertified for the second welding device, the welding operator is notcertified for the second welding device).

The control circuitry 320 may be configured to receive a request for thefirst welding process certification status, the second welding processcertification status, the first welding device certification status,and/or the second welding device certification status of the weldingoperator. Furthermore, the control circuitry 320 may be configured toprovide a response to the request. The response to the request mayinclude the first welding process certification status, the secondwelding process certification status, the first welding devicecertification status, and/or the second welding device certificationstatus of the welding operator. In certain embodiments, the weldingoperator may be authorized to use a first welding process, a secondwelding process, a first welding device, and/or a second welding devicebased at least partly on the response. Furthermore, in some embodiments,the first welding process, the second welding process, the first weldingdevice, and/or the second welding device of a welding system may beenabled or disabled based at least partly on the response. Moreover, incertain embodiments, the first welding process, the second weldingprocess, the first welding device, and/or the second welding device of awelding system may be enabled or disabled automatically. Thus, a weldingoperator's certification data may be used to enable and/or disable thatwelding operator's ability to use a particular welding system, weldingdevice, and/or welding process. For example, a welding operator may havea certification for a first welding process, but not for a secondwelding process. Accordingly, in certain embodiments, a welding operatormay verify their identity at a welding system (e.g., by logging in orsome other form of authentication). After the identity of the weldingoperator is verified, the welding system may check the weldingoperator's certification status. The welding system may enable thewelding operator to perform operations using the first welding processbased on the welding operator's certification status, but may block thewelding operator from performing the second welding process based on thewelding operator's certification status.

FIG. 20 is an embodiment of a screen 327 illustrating data correspondingto a weld. The screen 327 may be produced by the welding software 244and may be displayed on the display 32. The screen 327 illustratesparameters that may be graphically displayed to a welding operatorbefore, during, and/or after performing a welding operation. Forexample, the parameters may include a work angle 328, a travel angle330, a contact tip to workpiece distance 332, a welding torch travelspeed 334, a proximity of the welding torch in relation to the workpiece336, a welding voltage 337, a welding current 338, a welding torchorientation, a welding torch position, an aim of the welding torch, andso forth.

As illustrated, graphically illustrated parameters may include anindication 339 of a current value of a parameter (e.g., while performinga welding assignment). Furthermore, a graph 340 may show a history ofthe value of the parameter, and a score 341 may show an overallpercentage that corresponds to how much time during the weldingassignment that the welding operator was within a range of acceptablevalues. In certain embodiments, a video replay 342 of a weldingassignment may be provided on the screen 327. The video replay 342 mayshow live video of a welding operator performing a real weld, live videoof the welding operator performing a simulated weld, live video of thewelding operator performing a virtual reality weld, live video of thewelding operator performing an augmented reality weld, live video of awelding arc, live video of a weld puddle, and/or simulated video of awelding operation.

In certain embodiments, the welding system 10 may capture video dataduring a welding assignment, and store the video data on the storagedevice 24. Moreover, the welding software 244 may be configured toretrieve the video data from the storage device 24, to retrieve weldingparameter data from the storage device 24, to synchronize the video datawith the welding parameter data, and to provide the synchronized videoand welding parameter data to the display 32.

The welding software 244 may analyze welding parameter data to determinea traversed path 344 that may be shown on the display 32. In someembodiments, a time 346 during a weld may be selected by a weldingoperator. By selecting the time 346, the welding operator may view thevideo replay 342 and/or the traversed path 344 in conjunction with thewelding parameters as they were at the selected time 346 in order toestablish a correlation between the welding parameters, the video replay342, and/or the traversed path 344. The welding software 244 may beconfigured to recreate welding data based at least partly on weldingparameter data, to synchronize the video replay 342 with the recreatedwelding data, and to provide the synchronized video replay 342 andrecreated welding data to the display 32. In certain embodiments, therecreated welding data may be weld puddle data and/or a simulated weld.

In certain embodiments, the storage device 24 may be configured to storea first data set corresponding to multiple welds performed by a weldingoperator, and to store a second data set corresponding to multiplenon-training welds performed by the welding operator. Furthermore, thecontrol circuitry 320 may be configured to retrieve at least part of thefirst data set from the storage device 24, to retrieve at least part ofthe second data set from the storage device 24, to synchronize the atleast part of the first data set with the at least part of the seconddata set, and to provide the synchronized at least part of the firstdata set and at least part of the second data set to the display 32.

FIG. 21 is an embodiment of a screen 347 illustrating a discontinuityanalysis 348 of a weld. The discontinuity analysis 348 includes alisting 350 that may itemize potential issues with a welding operation.The discontinuity analysis 348 provides feedback to the welding operatorregarding time periods within the welding operation in which the welddoes not meet a predetermined quality threshold. For example, betweentimes 352 and 354, there is a high discontinuity (e.g., the weldingquality is poor, the weld has a high probability of failure, the weld isdefective). Furthermore, between times 356 and 358, there is a mediumdiscontinuity (e.g., the welding quality is average, the weld has amedium probability of failure, the weld is partially defective).Moreover, between times 360 and 362, there is a high discontinuity, andbetween times 364 and 366, there is a low discontinuity (e.g., thewelding quality is good, the weld has a low probability of failure, theweld is not defective). With this information a welding operator may beable to quickly analyze the quality of a welding operation.

FIG. 22 is a block diagram of an embodiment of a welding instructorscreen 368 of the welding software 244. The welding software 244 isconfigured to provide training simulations for many different weldingconfigurations. For example, the welding configurations may include aMIG welding process 370, a TIG welding process 372, a stick weldingprocess 374, the live-arc welding mode 346, the simulation welding mode248, the virtual reality welding mode 250, and/or the augmented realitywelding mode 252.

The welding instructor screen 368 may be configured to enable a weldinginstructor to restrict training of a welding operator 376 (e.g., to oneor more selected welding configurations), to restrict training of aclass of welding operators 378 (e.g., to one or more selected weldingconfigurations), and/or to restrict training of a portion of a class ofwelding operators 380 (e.g., to one or more selected weldingconfigurations). Moreover, the welding instructor screen 368 may beconfigured to enable the welding instructor to assign selected trainingassignments to the welding operator 382, to assign selected trainingassignments to a class of welding operators 384, and/or to assignselected training assignments to a portion of a class of weldingoperators 386. Furthermore, the welding instructor screen 368 may beconfigured to enable the welding instructor to automatically advance thewelding operator (or a class of welding operators) from a firstassignment to a second assignment 388. For example, the welding operatormay advance from a first assignment to a second assignment based atleast partly on a quality of performing the first assignment.

FIG. 23 is an embodiment of a method 389 for weld training usingaugmented reality. A welding operator may select a mode of the weldingsoftware 244 (block 390). The welding software 244 determines whetherthe augmented reality mode 252 has been selected (block 392). If theaugmented reality mode 252 has been selected, the welding software 244executes an augmented reality simulation. It should be noted that thewelding operator may be wearing a welding helmet and/or some otherheadgear configured to position a display device in front of the weldingoperator's view. Furthermore, the display device may generally betransparent to enable the welding operator to view actual objects;however, a virtual welding environment may be portrayed on portions ofthe display device. As part of this augmented reality simulation, thewelding software 244 receives a position and/or an orientation of thewelding torch 14, such as from the sensing device 16 (block 394). Thewelding software 244 integrates the virtual welding environment with theposition and/or the orientation of the welding torch 14 (block 396).Moreover, the welding software 244 provides the integrated virtualwelding environment to the display device (block 398). For example, thewelding software 244 may determine where a weld bead should bepositioned within the welding operator's field of view, and the weldingsoftware 244 may display the weld bead on the display device such thatthe weld bead appears to be on a workpiece. After completion of theweld, the augmented reality simulation may enable the welding operatorto erase a portion of the virtual welding environment (e.g., the weldbead) (block 400), and the welding software 244 returns to block 390.

If the augmented realty mode 252 has not been selected, the weldingsoftware 244 determines whether the live-arc mode 246 has been selected(block 402). If the live-arc mode 246 has been selected, the weldingsoftware 244 enters the live-arc mode 246 and the welding operator mayperform the live-arc weld (block 404). If the live-arc mode 246 has notbeen selected and/or after executing block 404, the welding software 244returns to block 390. Accordingly, the welding software 244 isconfigured to enable a welding operator to practice a weld in theaugmented reality mode 252, to erase at least a portion of the virtualwelding environment from the practice weld, and to perform a live weldin the live-arc mode 246. In certain embodiments, the welding operatormay practice the weld in the augmented reality mode 252 consecutively amultiple number of times.

FIG. 24 is an embodiment of another method 406 for weld training usingaugmented reality. A welding operator may select a mode of the weldingsoftware 244 (block 408). The welding software 244 determines whetherthe augmented reality mode 252 has been selected (block 410). If theaugmented reality mode 252 has been selected, the welding software 244executes an augmented reality simulation. It should be noted that thewelding operator may be wearing a welding helmet and/or some otherheadgear configured to position a display device in front of the weldingoperator's view. Furthermore, the display device may completely blockthe welding operator's field of vision such that images observed by thewelding operator have been captured by a camera and displayed on thedisplay device. As part of this augmented reality simulation, thewelding software 244 receives an image of the welding torch 14, such asfrom the sensing device 16 (block 412). The welding software 244integrates the virtual welding environment with the image of the weldingtorch 14 (block 414). Moreover, the welding software 244 provides theintegrated virtual welding environment with the image of the weldingtorch 14 to the display device (block 416). For example, the weldingsoftware 244 may determine where a weld bead should be positioned withinthe welding operator's field of view and the welding software 244displays the weld bead on the display device with the image of thewelding torch 14 and other objects in the welding environment. Aftercompletion of the weld, the augmented reality simulation may enable thewelding operator to erase a portion of the virtual welding environment(e.g., the weld bead) (block 418), and the welding software 244 returnsto block 408.

If the augmented realty mode 252 has not been selected, the weldingsoftware 244 determines whether the live-arc mode 246 has been selected(block 420). If the live-arc mode 246 has been selected, the weldingsoftware 244 enters the live-arc mode 246 and the welding operator mayperform the live-arc weld (block 422). If the live-arc mode 246 has notbeen selected and/or after executing block 422, the welding software 244returns to block 408. Accordingly, the welding software 244 isconfigured to enable a welding operator to practice a weld in theaugmented reality mode 252, to erase at least a portion of the virtualwelding environment from the practice weld, and to perform a live weldin the live-arc mode 246. In certain embodiments, the welding operatormay practice the weld in the augmented reality mode 252 consecutively amultiple number of times.

FIG. 25 is a block diagram of an embodiment of the welding torch 14. Thewelding torch 14 includes the control circuitry 52, the user interface60, and the display 62 described previously. Furthermore, the weldingtorch 14 includes a variety of sensors and other devices. In particular,the welding torch 14 includes a temperature sensor 424 (e.g.,thermocouple, thermistor, etc.), a motion sensor 426 (e.g.,accelerometer, gyroscope, magnetometer, etc.), and a vibration device428 (e.g., vibration motor). In certain embodiments, the welding torch14 may include more than one temperature sensor 424, motion sensor 426,and/or vibration device 428.

During operation, the welding torch 14 may be configured to use thetemperature sensor 424 to detect a temperature associated with thewelding torch 14 (e.g., a temperature of electronic components of thewelding torch 14, a temperature of the display 62, a temperature of alight-emitting device, a temperature of the vibration device, atemperature of a body portion of the welding torch 14, etc.). Thecontrol circuitry 52 (or control circuitry of another device) may usethe detected temperature to perform various events. For example, thecontrol circuitry 52 may be configured to disable use of the live-arcmode 246 (e.g., live welding) by the welding torch 14 if the detectedtemperature reaches and/or surpasses a predetermined threshold (e.g.,such as 85° C.). Moreover, the control circuitry 52 may also beconfigured to disable various heat producing devices of the weldingtorch 14, such as the vibration device 428, light-emitting devices, andso forth. The control circuitry 52 may also be configured to show amessage on the display 62, such as “Waiting for torch to cool down.Sorry for the inconvenience.” In certain embodiments, the controlcircuitry 52 may be configured to disable certain components or featuresif the detected temperature reaches a first threshold and to disableadditional components or features if the detected temperature reaches asecond threshold.

Moreover, during operation, the welding torch 14 may be configured touse the motion sensor 426 to detect a motion (e.g., acceleration, etc.)associated with the welding torch 14. The control circuitry 52 (orcontrol circuitry of another device) may use the detected accelerationto perform various events. For example, the control circuitry 52 may beconfigured to activate the display 62 (or another display) after themotion sensor 426 detects that the welding torch 14 has been moved.Accordingly, the control circuitry 52 may direct the display 62 to “wakeup,” such as from a sleep mode and/or to exit a screen saver mode tofacilitate a welding operator of the welding torch 14 using a graphicaluser interface (GUI) on the display 62.

In certain embodiments, the control circuitry 52 may be configured todetermine that a high impact event (e.g., dropped, used as a hammer,etc.) to the welding torch 14 has occurred based at least partly on thedetected motion. Upon determining that a high impact event has occurred,the control circuitry 52 may store (e.g., log) an indication that thewelding torch 14 has been impacted. Along with the indication, thecontrol circuitry 52 may store other corresponding data, such as a date,a time, an acceleration, a user name, welding torch identification data,and so forth. The control circuitry 52 may also be configured to show anotice on the display 62 to a welding operator requesting that theoperator refrain from impacting the welding torch 14. In someembodiments, the control circuitry 52 may be configured to use themotion detected by the motion sensor 426 to enable the welding operatorto navigate and/or make selections within a software user interface(e.g., welding software, welding training software, etc.). For example,the control circuitry 52 may be configured to receive the accelerationand to make a software selection if the acceleration matches apredetermined pattern (e.g., the acceleration indicates a jerky motionin a certain direction, the acceleration indicates that the weldingtorch 14 is being shaken, etc.).

The vibration device 428 is configured to provide feedback to a weldingoperator by directing the welding torch 14 to vibrate and/or shake(e.g., providing vibration or haptic feedback). The vibration device 428may provide vibration feedback during live welding and/or duringsimulated welding. As may be appreciated, vibration feedback during livewelding may be tuned to a specific frequency to enable a weldingoperator to differentiate between vibration that occurs due to livewelding and the vibration feedback. For example, vibration feedback maybe provided at approximately 3.5 Hz during live welding. Using such afrequency may enable a welding operator to detect when vibrationfeedback is occurring at the same time that natural vibration occur dueto live welding. Conversely, vibration feedback may be provided atapproximately 9 Hz during live welding. However, the 9 Hz frequency maybe confused with natural vibration that occurs due to live welding.

FIG. 26 is an embodiment of a method 430 for providing vibrationfeedback to a welding operator using the welding torch 14. The controlcircuitry 52 (or control circuitry of another device) detects aparameter (e.g., work angle, travel angle, travel speed, tip-to-workdistance, aim, etc.) corresponding to a welding operation (block 432).As may be appreciated, the welding operation may be a live weldingoperation, a simulated welding operation, a virtual reality weldingoperation, and/or an augmented reality welding operation. The controlcircuitry 52 determines whether the parameter is within a firstpredetermined range (block 434). As may be appreciated, the firstpredetermined range may be a range that is just outside of an acceptablerange. For example, the parameter may be work angle, the acceptablerange may be 45 to 50 degrees, and the first predetermined range may be50 to 55 degrees. Accordingly, in such an example, the control circuitry52 determines whether the work angle is within the first predeterminedrange of 50 to 55 degrees.

If the parameter is within the first predetermined range, the controlcircuitry 52 vibrates the welding torch at a first pattern (block 436).The first pattern may be a first frequency, a first frequencymodulation, a first amplitude, and so forth. Moreover, if the parameteris not within the first predetermined range, the control circuitry 52determines whether the parameter is within a second predetermined range(block 438). The second predetermined range may be a range that is justoutside of the first predetermined range. For example, continuing theexample discussed above, the second predetermined range may be 55 to 60degrees. Accordingly, in such an example, the control circuitry 52determines whether the work angle is within the second predeterminedrange of 55 to 60 degrees. If the parameter is within the secondpredetermined range, the control circuitry 52 vibrates the welding torchat a second pattern (block 440). The second pattern may be a secondfrequency, a second frequency modulation, a second amplitude, and soforth. It should be noted that the second pattern is typically differentthan the first pattern. In certain embodiments, the first and secondpatterns may be the same. Furthermore, audible indications may beprovided to the welding operator to indicate whether the parameter iswithin the first predetermined range or within the second predeterminedrange. In addition, audible indications may be used to indicate aparameter that is not within an acceptable range. In such embodiments,vibration may be used to indicate that a welding operator is doingsomething wrong, and audible indications may be used to identify whatthe welding operator is doing wrong and/or how to fix it. The parametermay be any suitable parameter, such as a work angle, a travel angle, atravel speed, a tip-to-work distance, and/or an aim. FIGS. 27 through 29illustrate embodiments of various patterns.

FIG. 27 is a graph 442 of an embodiment of two patterns each including adifferent frequency for providing vibration feedback to a weldingoperator. A first pattern 444 is separated from a second pattern 446 bytime 448. In the illustrated embodiment, the first pattern 444 is afirst frequency and the second pattern 446 is a second frequency that isdifferent from the first frequency. The first and second frequencies maybe any suitable frequency. As may be appreciated, the first and secondfrequencies may be configured to be different than a natural frequencyproduced during live welding to facilitate a welding operatordifferentiating between the natural frequency and the first and secondfrequencies. Although the illustrated embodiment shows the firstfrequency being lower than the second frequency, in other embodiments,the second frequency may be lower than the first frequency.

FIG. 28 is a graph 450 of an embodiment of two patterns each including adifferent modulation for providing vibration feedback to a weldingoperator. A first pattern 452 is separated from a second pattern 454 bytime 456. In the illustrated embodiment, the first pattern 452 is afirst modulation and the second pattern 454 is a second modulation thatis different from the first modulation. The first and second modulationmay be any suitable modulation. For example, the first modulation mayinclude a first number of vibration pulses (e.g., two pulses) and thesecond modulation may include a second number of vibration pulses (e.g.,three pulses). Moreover, the modulation may vary a number of pulses, atime between pulses, etc. In certain embodiments, a number of vibrationpulses and/or a time between pulses may be configured to graduallyincrease or decrease as a parameter moves toward or away from acceptableparameter values. Although the illustrated embodiment shows the firstmodulation as having fewer pulses than the second modulation, in otherembodiments, the second modulation may have fewer pulses than the firstmodulation.

FIG. 29 is a graph 458 of an embodiment of two patterns each including adifferent amplitude for providing vibration feedback to a weldingoperator. A first pattern 460 is separated from a second pattern 462 bytime 464. In the illustrated embodiment, the first pattern 460 is afirst amplitude and the second pattern 462 is a second amplitude that isdifferent from the first amplitude. The first and second amplitudes maybe any suitable amplitude. Although the illustrated embodiment shows thefirst amplitude being lower than the second amplitude, in otherembodiments, the second amplitude may be lower than the first amplitude.

FIG. 30 is a perspective view of an embodiment of the welding torch 14having spherical markers that may be used for tracking the welding torch14. The welding torch 14 includes a housing 466 that encloses thecontrol circuitry 52 of the welding torch 14 and/or any other componentsof the welding torch 14. The display 62 and user interface 60 areincorporated into a top portion of the housing 466.

As illustrated, a neck 470 extends from the housing 466 of the weldingtorch 14. Markers for tracking the welding torch 14 may be disposed onthe neck 470. Specifically, a mounting bar 472 is used to couple markers474 to the neck 470. The markers 474 are spherical markers in theillustrated embodiment; however, in other embodiments, the markers 474may be any suitable shape (e.g., such as a shape of an LED). The markers474 are used by the sensing device 16 for tracking the position and/orthe orientation of the welding torch 14. As may be appreciated, three ofthe markers 474 are used to define a first plane. Moreover, the markers474 are arranged such that a fourth marker 474 is in a second planedifferent than the first plane. Accordingly, the sensing device 16 maybe used to track the position and/or the orientation of the weldingtorch 14 using the four markers 474. It should be noted that while theillustrated embodiment shows four markers 474, the mounting bar 472 mayhave any suitable number of markers 474.

In certain embodiments, the markers 474 may be reflective markers, whilein other embodiments the markers 474 may be light-emitting markers(e.g., light-emitting diodes LEDs). In embodiments in which the markers474 are light-emitting markers, the markers 474 may be powered byelectrical components within the housing 466 of the welding torch 14.For example, the markers 474 may be powered by a connection 476 betweenthe mounting bar 472 and the housing 466. Furthermore, the controlcircuitry 52 (or control circuitry of another device) may be used tocontrol powering on and/or off (e.g., illuminating) the markers 474. Incertain embodiments, the markers 474 may be individually powered onand/or off based on the position and/or the orientation of the weldingtorch 14. In other embodiments, the markers 474 may be powered on and/oroff in groups based on the position and/or the orientation of thewelding torch 14. It should be noted that in embodiments that do notinclude the mounting bar 472, the connection 476 may be replaced withanother marker 468 on a separate plane than the illustrated markers 468.

FIG. 31 is an embodiment of a method 478 for displaying on a display ofa welding torch a welding parameter in relation to a threshold. In theillustrated embodiment, the control circuitry 52 (or control circuitryof another device) receives a selection made by a welding operator of awelding parameter associated with a position, an orientation, and/or amovement of the welding torch 14 (block 480). For example, the weldingoperator may select a button on the user interface 60 of the weldingtorch 14 to select a welding parameter. The welding parameter may be anysuitable welding parameter, such as a work angle, a travel angle, atravel speed, a tip-to-work distance, an aim, and so forth. As may beappreciated, the welding system 10 may select the welding parameterautomatically without input from a welding operator. After the selectionis made, the display 62 of the welding torch 14 displays or shows arepresentation of the welding parameter in relation to a predeterminedthreshold range and/or target value for the welding parameter (block482). The displayed welding parameter is configured to change as theposition of the welding torch 14 changes, as the orientation of thewelding torch 14 changes, and/or as movement of the welding torch 14changes. Thus, the welding operator may use the welding torch 14 toproperly position and/or orient the welding torch 14 while performing(e.g., prior to beginning, starting, stopping, etc.) a weldingoperation, thereby enabling the welding operator to perform the weldingoperation with the welding parameter within the predetermined thresholdrange or at the target value.

For example, the welding operator may desire to begin the weldingoperation with a proper work angle. Accordingly, the welding operatormay select “work angle” on the welding torch 14. After “work angle” isselected, the welding operator may position the welding torch 14 at adesired work angle. As the welding operator moves the welding torch 14,a current work angle is displayed in relation to a desired work angle.Thus, the welding operator may move the welding torch 14 around untilthe current work angle matches the desired work angle and/or is within adesired range of work angles. As may be appreciated, the display 62 maybe turned off and/or darkened so that it is blank during a weldingoperation. However, a welding operator may select a desired weldingparameter prior to performing the welding operation. Even with thedisplay 62 blank, the control circuitry 52 may be configured to monitorthe welding parameter and provide feedback to the welding operatorduring the welding operation (e.g., vibration feedback, audio feedback,etc.).

FIG. 32 is an embodiment of a set of screenshots of the display 62 ofthe welding torch 14 for showing a welding parameter in relation to athreshold. The set of screenshots illustrate various ways that weldingparameters are displayed for a welding operator for performing a weldingoperation. As may be appreciated, in certain embodiments, the weldingparameters may be displayed to the welding operator before, during,and/or after the welding operation. Screen 484 illustrates a work anglethat is not within a predetermined threshold range. A parameter portion486 of the display 62 indicates the selected parameter. Moreover, arange section 488 indicates whether the selected parameter is within thepredetermined threshold range. Furthermore, a parameter value section490 indicates the value of the selected parameter. On the screen 484,the work angle of 38 is out of range as indicated by the arrow extendingoutward from the central circle. Screen 492 illustrates a work angle of45 that is within the predetermined threshold range as indicated by noarrow extending from the central circle.

As may be appreciated, the sensing device 16 may be configured to detectwhether the travel angle is a drag angle (e.g., the travel angle isahead of the welding arc) or a push angle (e.g., the travel anglefollows behind the welding arc). Accordingly, screen 494 illustrates adrag travel angle of 23 that is outside of a predetermined thresholdrange as indicated by an arrow extending outward from a central circle.Conversely, screen 496 illustrates a push travel angle of 15 that iswithin the predetermined threshold range as indicated by no arrowextending from the central circle. Furthermore, screen 498 illustrates atravel speed of 12 that is within of a predetermined threshold range asindicated by a vertical line aligned with the central circle.Conversely, screen 500 illustrates a travel speed of 18 that is outsideof the predetermined threshold range as indicated by the vertical lineto the right of the central circle.

Screen 502 illustrates a tip-to-work distance of 1.5 that is greaterthan a predetermined threshold range as indicated by a small circlewithin an outer band. Moreover, screen 504 illustrates the tip-to-workdistance of 0.4 that is less than a predetermined threshold range asindicated by the circle outside of the outer band. Furthermore, screen506 illustrates the tip-to-work distance of 1.1 that is within thepredetermined threshold range as indicated by the circle substantiallyfilling the area within the outer band. Moreover, screen 508 illustratesan aim of 0.02 that is within a predetermined threshold range asindicated by a horizontal line aligned with a central circle.Conversely, screen 510 illustrates an aim of 0.08 that is not within thepredetermined threshold range as indicated by the horizontal line towardthe top part of the central circle. While specific graphicalrepresentations have been shown on the display 62 in the illustratedembodiment for showing a welding parameter in relation to a threshold,other embodiments may use any suitable graphical representations forshowing a welding parameter in relation to a threshold. Moreover, incertain embodiments individual parameter visual guides may be combinedso that multiple parameters are visually displayed together.

Furthermore, in certain embodiments, the welding system 10 may detect ifthe welding torch 14 is near and/or far from a welding joint. Being nearthe welding joint is a function of the contact tip-to-work distance(CTWD) and aim parameters. When both the CTWD and aim parameters arewithin suitable predetermined ranges, the welding system 10 may considerthe welding torch 14 near the welding joint. Moreover, when the weldingtorch 14 is near the welding joint, the visual guides may be displayedon the welding torch 14. When the welding torch 14 is near the weldingjoint and in the live welding mode, a message (e.g., warning message)may be displayed on a display indicating that proper welding equipment(e.g., welding helmet, etc.) should be in place as a safety precautionfor onlookers. However, an external display may continue to display thereal-time data at a safe distance from the welding operation. Moreover,in some embodiments, when the welding torch 14 is near the welding jointand in the live welding mode, the display of the welding torch 14 may bechanged (e.g., to substantially blank and/or clear, to a non-distractingview, to a predetermined image, etc.) while a welding operator actuatesthe trigger of the welding torch 14. When the welding torch 14 is farfrom the welding joint, actuating the trigger of the welding torch 14will not perform (e.g., begin) a test run. Furthermore, when the weldingtorch 14 is far from the welding joint, actuating the welding torch 14will have no effect in a non-live welding mode, and may feed weldingwire in the live welding mode without beginning a test run.

FIG. 33 is an embodiment of a method 512 for tracking the welding torch14 in the welding system 10 using at least four markers. One or morecameras (e.g., such as one or more cameras of the sensing system 16) areused to detect the markers of the welding torch 14 (block 514). Asdiscussed above, the markers may be reflective markers and/orlight-emitting markers. Furthermore, the markers may include four ormore markers to facilitate determining an accurate position and/ororientation of the welding torch 14. One or more processors 20 of thecomputer 18 (or other processors) may be used with the sensing system 16to track the position of the welding torch 14 and/or the orientation ofthe welding torch 14 based on the detected markers (block 516). If theone or more cameras are unable to detect one or more of the markers, theone or more processors 20 (or control circuitry, such as the controlcircuitry 52) may be configured to block live welding while the one ormore cameras are unable to detect the markers (block 518). Moreover, thedisplay 62 of the welding torch 14 may be configured to display amessage indicating that the markers are not detected while the one ormore cameras are unable to detect the markers of the welding torch 14(block 520). Accordingly, live welding using the welding torch 14 may beblocked if the welding torch 14 is unable to be tracked by the sensingsystem 16.

FIG. 34 is an embodiment of a method 522 for detecting the ability forthe processor 20 (or any other processor) to communicate with thewelding torch 14. The welding torch 14 is configured to detect a signalfrom the processor 20 (block 524). The signal is provided from theprocessor 20 to the welding torch 14 at a predetermined interval. Incertain embodiments, the signal may be a pulsed signal provided from theprocessor 20 to the welding torch 14 at the predetermined interval.Moreover, the signal is provided to the welding torch 14 so that thewelding torch 14 is able to determine that the welding torch 14 is ableto communicate with the processor 20. If the welding torch 14 does notreceive the signal from the processor 20 within the predeterminedinterval, control circuitry 52 (or control circuitry of another device)is configured to block live welding using the welding torch 14 while thesignal is not detected (block 526). Moreover, the display 62 may beconfigured to display a message indicating that the signal from theprocessor 20 is not detected while the live welding is blocked (block528). Accordingly, the welding torch 14 may detect the ability for theprocessor 20 to communicate with the welding torch 14.

FIG. 35 is an embodiment of a method 530 for calibrating a curved weldjoint that may be used with the welding system 10. One or more cameras(e.g., such as one or more cameras of the sensing system 16) are used todetect a first position (e.g., first calibration point) of the curvedweld joint (block 532). For example, a calibration tool and/or thewelding torch 14 may be used to identify the first position of thecurved weld joint to the one or more cameras (e.g., such as by touchinga tip of the calibration tool and/or the welding torch 14 to the firstposition). In addition, the one or more cameras may be used to track thecalibration tool and/or the welding torch 14 to determine a positionand/or an orientation of the calibration tool and/or the welding torch14 for detecting the first position of the curved weld joint.

Moreover, the one or more cameras are used to detect a second position(e.g., second calibration point) of the curved weld joint (block 534).For example, the calibration tool and/or the welding torch 14 may beused to identify the second position of the curved weld joint to the oneor more cameras. In addition, the one or more cameras may be used totrack the calibration tool and/or the welding torch 14 to determine aposition and/or an orientation of the calibration tool and/or thewelding torch 14 for detecting the second position of the curved weldjoint. Furthermore, the one or more cameras are used to detect a curvedportion of the curved weld joint between the first and second positionsof the curved weld joint (block 536). For example, the calibration tooland/or the welding torch 14 may be used to identify the curved weldjoint between the first and second positions of the curved weld joint.In addition, the one or more cameras may be used to track thecalibration tool and/or the welding torch 14 to determine a positionand/or an orientation of the calibration tool and/or the welding torch14 for detecting the curved portion of the curved weld joint. As may beappreciated, during operation, the first position may be detected, thenthe curved weld joint may be detected, and then the second position maybe detected. However, the detection of the first position, the secondposition, and the curved weld joint may occur in any suitable order. Incertain embodiments, a representation of the curved portion of thecurved weld joint may be stored for determining a quality of a weldingoperation by comparing a position and/or an orientation of the weldingtorch 14 during the welding operation to the stored representation ofthe curved portion of the curved weld joint. As may be appreciated, incertain embodiments, the welding operation may be a multi-pass weldingoperation.

Moreover, calibration for some joints, such as circular weld joints(e.g., pipe joints) may be performed by touching the calibration tool tothree different points around the circumference of the circular weldjoint. A path of the circular weld joint may then be determined bycalculating a best-fit circle that intersects all three points. The pathof the circular weld joint may be stored and used to evaluate weldingparameters of training welds. For a more complex geometry, thecalibration tool might be dragged along the entire joint in order toindicate the joint to the system so that all of the parameters may becalculated.

FIG. 36 is a diagram of an embodiment of a curved weld joint 538. Such acurved weld joint 538 may be calibrated using the method 530 describedin FIG. 35. The curved weld joint 538 is on a workpiece 540.Specifically, the curved weld joint 538 includes a first position 542, asecond position 544, and a curved portion 546. Using the method 530, ashape of the curved weld joint 538 may be determined and/or stored forevaluating a welding operator performing a welding operation on thecurved weld joint 538.

FIG. 37 is an embodiment of a method 548 for tracking a multi-passwelding operation. One or more cameras (e.g., such as one or morecameras of the sensing system 16) are used to detect a first pass of thewelding torch 14 along a weld joint during the multi-pass weldingoperation (block 550). Moreover, the one or more cameras are used todetect a second pass of the welding torch 14 along the weld joint duringthe multi-pass welding operation (block 552). Furthermore, the one ormore cameras are used to detect a third pass of the welding torch 14along the weld joint during the multi-pass welding operation (block554). The control circuitry 52 (or control circuitry of another device)may be configured to store a representation of the first pass, thesecond pass, and/or the third pass together as a single weldingoperation for determining a quality of the multi-pass welding operation.As may be appreciated, the multi-pass welding operation may be a livewelding operation, a training welding operation, a virtual realitywelding operation, and/or an augmented reality welding operation.

FIG. 38 is a perspective view of an embodiment of the welding stand 12.The welding stand 12 includes the welding surface 88 supported by thelegs 90. Moreover, the welding surface 88 includes one or more slots 91to facilitate positioning of a workpiece on the welding surface 88.Furthermore, the welding surface 88 includes multiple apertures 556(e.g., holes or openings) that extend through the welding surface 88.The apertures 556 may be used to enable the sensing device 16 todetermine a position and/or an orientation of the welding surface 88.Specifically, markers may be arranged below the apertures 556, yetwithin the view of the sensing device 16 to enable the sensing device 16to determine the position and/or the orientation of the welding surface88. The markers may be arranged below the welding surface 88 tofacilitate longer lasting markers and/or to block debris from coveringthe markers, as explained in greater detail in relation to FIG. 39.

Drawers 558 are attached to the welding stand 12 to enable storage ofvarious components with the welding stand 12. Moreover, wheels 560 arecoupled to the welding stand 12 to facilitate easily moving the weldingstand 12. Adjacent to the drawers 558, a calibration tool holder 562 anda welding torch holder 564 enable storage of a calibration tool and thewelding torch 14. In certain embodiments, the welding system 10 may beconfigured to detect that the calibration tool is in the calibrationtool holder 562 at various times, such as before performing a weldingoperation. A support structure 566 extending vertically from the weldingsurface 88 is used to provide structure support to the sensing device 16and the display 32. Moreover, a tray 568 is coupled to the supportstructure 566 to facilitate storage of various components.

The protective cover 102 is positioned over the display 32 to blockcertain environmental elements from contacting the display 32 (e.g.,weld spatter, smoke, sparks, heat, etc.). A handle 570 is coupled to theprotective cover 102 to facilitate rotation of the protective cover 102from a first position (as illustrated) used to block certainenvironmental elements from contacting the display 32 to a second raisedposition away from the display 32, as illustrated by arrows 572. Thesecond position is not configured to block the environmental elementsfrom contacting the display 32. In certain embodiments, the protectivecover 102 may be held in the first and/or the second position by alatching device, a shock, an actuator, a stop, and so forth.

A switch 573 is used to detect whether the protective cover 102 is inthe first position or in the second position. Moreover, the switch 573may be coupled to the control circuitry 52 (or control circuitry ofanother device) and configured to detect whether the protective cover102 is in the first or the second position and to block or enablevarious operations (e.g., live welding, auxiliary power, etc.) while theswitch 573 detects that the protective cover 102 is in the first and/orthe second position. For example, if the switch 573 detects that theprotective cover 102 is in the second position (e.g., not properlycovering the display 32), the control circuitry 52 may block livewelding and/or simulation welding (with the protective cover 102 in thesecond position the sensing device 16 may be unable to accurately detectmarkers). As another example, if the switch 573 detects that theprotective cover 102 is in the second position, control circuitry of thewelding stand 12 may block the availability of power provided to anoutlet 574 of the welding stand 12. In certain embodiments, the display32 may show an indication that the protective cover 102 is in the firstand/or the second position. For example, while the protective cover 102is in the second position, the display 32 may provide an indication tothe welding operator that live welding and/or power at the outlet 574are unavailable. The welding stand 12 includes speakers 575 to enableaudio feedback to be provided to a welding operator using the weldingstand 12. Furthermore, in certain embodiments, if the trigger of thewelding torch 14 is actuated while the protective cover 102 is in thesecond position, the welding system 10 may provide visual and/or audiofeedback to the operator (e.g., the welding system 10 may provide avisual message and an audible sound effect).

As illustrated, the support structure 566 includes a first arm 576 and asecond arm 578. The first and second arms 576 and 578 are rotatableabout the support structure 566 to enable the first and second arms 576and 578 to be positioned at a selected height for vertical and/oroverhead welding. In the illustrated embodiment, the first and secondarms 576 and 578 are independently (e.g., separately) rotatable relativeto one another so that the first arm 576 may be positioned at a firstvertical position while the second arm 578 may be positioned at a secondvertical position different from the first vertical position. In otherembodiments, the first and second arms 576 and 578 are configured torotate together. Moreover, in certain embodiments, the first and secondarms 576 and 578 may be rotated independently and/or together based on aselection by a welding operator. As may be appreciated, in otherembodiments, arms may not be coupled to the support structure 566, butinstead may be positioned at other locations, such as being positionedto extend vertically above one or more front legs, etc. Furthermore, insome embodiments, a structure may be coupled to the welding stand 12 tofacilitate a welding operator leaning and/or resting thereon (e.g., aleaning bar).

Each of the first and second arms 576 and 578 includes a shock 580 (oranother supporting device) that facilitates holding the first and secondarms 576 and 578 in selected vertical positions. Moreover, each of thefirst and second arms 576 and 578 includes a braking system 582configured to lock the first and second arms 576 and 578 individually inselected positions. In certain embodiments, the braking system 582 isunlocked by applying a force to a handle, a switch, a pedal, and/oranother device.

The workpiece 82 is coupled to the second arm 578 for overhead and/orvertical welding. Moreover, the first arm 576 includes the welding plate108 for overhead, horizontal, and/or vertical welding. As may beappreciated, the workpiece 82, the welding plate 108, and/or a clampused to hold the welding plate 108 may include multiple markers (e.g.,reflective and/or light emitting) to facilitate tracking by the sensingdevice 16. For example, in certain embodiments, the workpiece 82, thewelding plate 108, and/or the clamp may include three markers on onesurface (e.g., in one plane), and a fourth marker on another surface(e.g., in a different plane) to facilitate tracking by the sensingdevice 16. As illustrated, a brake release 584 is attached to each ofthe first and second arms 576 and 578 for unlocking each braking system582. In certain embodiments, a pull chain may extend downward from eachbrake release 584 to facilitate unlocking and/or lowering the first andsecond arms 576 and 578, such as while the brake release 584 of thefirst and second arms 576 and 578 are vertically above the reach of awelding operator. Thus, the welding operator may pull a handle of thepull chain to unlock the braking system 582 and/or to lower the firstand second arms 576 and 578.

As illustrated, the second arm 578 includes a clamp assembly 588 forcoupling the workpiece 82 to the second arm 578. Moreover, the clampassembly 588 includes multiple T-handles 590 for adjusting, tightening,securing, and/or loosening clamps and other portions of the clampassembly 588. In certain embodiments, the first arm 576 may also includevarious T-handles 590 for adjusting, tightening, securing, and/orloosening the welding plate 108. As may be appreciated, the clampassembly 588 may include multiple markers (e.g., reflective and/or lightemitting) to facilitate tracking by the sensing device 16. For example,in certain embodiments, the clamp assembly 588 may include three markerson one surface (e.g., in one plane), and a fourth marker on anothersurface (e.g., in a different plane) to facilitate tracking by thesensing device 16. It should be noted that the welding system 10 mayinclude the clamp assembly 588 on one or both of the first and secondarms 576 and 578.

The sensing device 16 includes a removable cover 592 disposed in frontof one or more cameras of the sensing device 16 to block environmentalelements (e.g., spatter, smoke, heat, etc.) or other objects fromcontacting the sensing device 16. The removable cover 592 is disposed inslots 594 configured to hold the removable cover 592 in front of thesensing device 16. In certain embodiments, the removable cover 592 maybe inserted, removed, and/or replaced without the use of tools. Asexplained in detail below, the removable cover 592 may be disposed infront of the sensing device 16 at an angle to facilitate infrared lightpassing therethrough.

As illustrated, a linking assembly 596 may be coupled between the firstand/or second arms 576 and 578 and the sensing device 16 to facilitaterotation of the sensing device 16 as the first and/or second arms 576and 578 are rotated. Accordingly, as the first and/or second arms 576and 578 are rotated, the sensing device 16 may also rotate such that oneor more cameras of the sensing device 16 are positioned to track aselected welding surface. For example, if the first and/or second arms576 and 578 are positioned in a lowered position, the sensing device 16may be configured to track welding operations that occur on the weldingsurface 88. On the other hand, if the first and/or second arms 576 and578 are positioned in a raised position, the sensing device 16 may beconfigured to track vertical, horizontal, and/or overhead weldingoperations. In some embodiments, the first and/or second arms 576 and578 and the sensing device 16 may not be mechanically linked, yetrotation of the first and/or second arms 576 and 578 may facilitaterotation of the sensing device 16. For example, markers on the firstand/or second arms 576 and 578 may be detected by the sensing device 16and the sensing device 16 may move (e.g., using a motor) based on thesensed position of the first and/or second arms 576 and 578.

FIG. 39 is a cross-sectional view of an embodiment of the weldingsurface 88 of the welding stand 12 of FIG. 38. As illustrated, thewelding surface 88 includes multiple apertures 556 extendingtherethrough between an upper plane 597 of the welding surface 88 and alower plane 598 of the welding surface 88. A bracket 599 is positionedbeneath each aperture 556. The brackets 599 may be coupled to thewelding surface 88 using any suitable fastener or securing means. In theillustrated embodiment, the brackets 599 are coupled to the weldingsurface 88 using fasteners 600 (e.g., bolts, screws, etc.). In otherembodiments, the brackets 599 may be welded, bonded, or otherwisesecured to the welding surface 88. Moreover, in certain embodiments, thebrackets 599 may be mounted to a lateral side of the welding stand 12rather than the welding surface 88. Markers 602 are coupled to thebrackets 599 and positioned vertically below the apertures 556, but themarkers 602 are horizontally offset from the apertures 556 to block dustand/or spatter from contacting the markers 602 and to enable the sensingdevice 16 to sense the markers 602. In some embodiments, the markers 602may be positioned within the apertures 556 and/or at any location suchthat the motion tracking system is positioned on one side of the upperplane 597 and the markers 602 are positioned on the opposite side of theupper plane 597. As may be appreciated, the markers 602 may be lightreflective and/or light-emissive. For example, in certain embodiments,the markers 602 may be formed from a light reflective tape. In someembodiments, the markers 602 may be spherical markers. Accordingly, thesensing device 16 may detect the markers 602 to determine a positionand/or an orientation of the welding surface 88.

FIG. 40 is a cross-sectional view of an embodiment of the sensing device16 having the removable cover 592. As illustrated, the removable cover592 is disposed in the slots 594. The sensing device 16 includes acamera 604 (e.g., infrared camera) having a face 605 on a side of thecamera 604 having a lens 606. The removable cover 592 is configured toenable infrared light to pass therethrough and to block environmentalelements (e.g., spatter, smoke, heat, etc.) or other objects fromcontacting the lens 606 of the camera 604. As may be appreciated, thecamera 604 may include one or more infrared emitters 607 configured toemit infrared light. If the removable cover 592 is positioned directlyin front of the face 605, a large amount of the infrared light from theinfrared emitters 607 may be reflected by the removable cover 592 towardthe lens 606 of the camera 604. Accordingly, the removable cover 592 ispositioned at an angle 608 relative to the face 605 of the camera 604 todirect a substantial portion of the infrared light from being reflectedtoward the lens 606. Specifically, in certain embodiments, the removablecover 592 may be positioned with the angle 608 between approximately 10to 60 degrees relative to the face 605 of the camera 604. Moreover, inother embodiments, the removable cover 592 may be positioned with theangle 608 between approximately 40 to 50 degrees (e.g., approximately 45degrees) relative to the face 605 of the camera 604. The removable cover592 may be manufactured from any suitable light-transmissive material.For example, in certain embodiments, the removable cover 592 may bemanufactured from a polymeric material, or any other suitable material.

FIG. 41 is a perspective view of an embodiment of a calibration tool610. As may be appreciated, the calibration tool 610 may be used tocalibrate a workpiece, a work surface, a weld joint, and so forth, for awelding operation. The calibration tool 610 includes a handle 612 tofacilitate gripping the calibration tool 610. Moreover, the calibrationtool 610 is configured to be detected by the sensing device 16 fordetermining a spatial position that a tip 614 of the calibration tool610 is contacting. In certain embodiments, the computer 18 coupled tothe sensing device 16 may be configured to determine a calibration pointmerely by the tip 614 contacting a specific surface. In otherembodiments, the computer 18 is configured to determine a calibrationpoint by a welding operator providing input indicating that the tip 614is contacting a calibration point. Furthermore, in the illustratedembodiment, the computer 18 is configured to detect a calibration pointby the tip 614 contacting the calibration point while a downward forceis applied to the calibration tool 610 via the handle. The downwardforce directs a distance between two adjacent markers to decrease belowa predetermined threshold thereby indicating a selected calibrationpoint. The sensing device 16 is configured to detect the change indistance between the two adjacent markers and the computer 18 isconfigured to use the change in distance to identify the calibrationpoint.

The handle 612 is coupled to a light-transmissive cover 616. Moreover, agasket 618 is coupled to one end of the light-transmissive cover 616,while an end cap 620 is coupled to an opposite end of thelight-transmissive cover 616. During operation, as a downward force isapplied to the calibration tool 610 using the handle 612, a distance 622between the tip 613 and the gasket 618 decreases.

FIG. 42 is a perspective view of the calibration tool 610 of FIG. 41having the outer cover 616 removed. The calibration tool 610 includes afirst portion 624 having a first shaft 626. Moreover, the first shaft626 includes the tip 614 on one end, and a bearing 628 (or mountingstructure) on an opposite end. In certain embodiments, the bearing 628has a cup like structure configured to fit around a contact tip of thewelding torch 14. Furthermore, the first shaft 626 includes a firstmarker 630 and a second marker 632 coupled thereto. The calibration tool610 also includes a second portion 634 having a second shaft 636 with athird marker 638 coupled thereto. A spring 640 is disposed around thesecond shaft 636 between the third marker 638 and the bearing 628. Asmay be appreciated, the spring 640 facilitates the third marker 638being directed toward the second marker 632. For example, as a downwardforce is applied to the calibration tool 610 using the handle 612, thespring 640 is compressed to decrease a first distance 642 between thesecond and third markers 632 and 638. In contrast, as the downward forceis removed from the calibration tool 610, the spring 640 is decompressedto increase the first distance 642 between the second and third markers632 and 638. A second distance 644 between the first and second markers630 and 632 is fixed, and a third distance 646 between the first marker630 and the tip 614 is also fixed.

In certain embodiments, the welding system 10 uses the calibration tool610 to detect calibration points using a predetermined algorithm. Forexample, the third distance 646 between the tip 614 and the closestmarker to the tip 614 (e.g., the first marker 630) is measured. Thethird distance 646 is stored in memory. The second distance 644 betweentwo fixed markers (e.g., the first marker 630 and the second marker 632)is measured. The second distance 644 is also stored in memory.Furthermore, a compressed distance between the markers (e.g., the secondand third markers 632 and 638) with the spring 640 disposed therebetweenis measured. A line is calculated between the two fixed markers usingtheir x, y, z locations. The line is used to project a vector along thatline with a length of the third distance 646 starting at the firstmarker 630 closest to the tip 614. The direction of the vector may beselected to be away from the compressed markers. Accordingly, the threedimensional location of the tip may be calculated using the markers. Insome embodiments, only two markers may be used by the calibration tool610. In such embodiments, an assumption may be made that the markerclosest to the tip 614 is the marker closest to the work surface (e.g.,table or clamp). Although the calibration tool 610 in the illustratedembodiment uses compression to indicate a calibration point, thecalibration tool 610 may indicate a calibration point in any suitablemanner, such as by uncovering a marker, covering a marker, turning on anLED (e.g., IR LED), turning off an LED (e.g., IR LED), enabling and/ordisabling a wireless transmission to a computer, and so forth.

The first, second, and third markers 630, 632, and 638 are spherical, asillustrated; however, in other embodiments, the first, second, and thirdmarkers 630, 632, and 638 may be any suitable shape. Moreover, thefirst, second, and third markers 630, 632, and 638 have a reflectiveouter surface and/or include a light-emitting device. Accordingly, thefirst, second, and third markers 630, 632, and 638 may be detected bythe sensing device 16. Therefore, the sensing device 16 is configured todetect the first, second, and third distances 642, 644, and 646. As thefirst distance 642 decreases below a predetermined threshold, thecomputer 18 is configured to identify a calibration point. As may beappreciated, the first, second, and third distances 642, 644, and 646are all different to enable the sensing device 16 and/or the computer 18to determine a location of the tip 614 using the location of first,second, and third markers 630, 632, and 638.

To calibrate a workpiece, the workpiece may first be clamped to thewelding surface 88. After the workpiece is clamped to the weldingsurface 88, a welding operator may provide input to the welding system10 to signify that the workpiece is ready to be calibrated. In certainembodiments, the clamp used to secure the workpiece to the weldingsurface 88 may include markers that facilitate the welding system 10detecting that the workpiece is clamped to the welding surface 88. Afterthe welding system 10 receives an indication that the workpiece isclamped to the welding surface 88, the welding operator uses thecalibration tool 610 to identify two calibration points. Specifically,in the illustrated embodiment, the welding operator touches the tip 614to a first calibration point and applies downward force using the handle612 until the welding system 10 detects a sufficient change in distancebetween adjacent markers, thereby indicating the first calibrationpoint. Furthermore, the welding operator touches the tip 614 to a secondcalibration point and applies downward force using the handle 612 untilthe welding system 10 detects a sufficient change in distance betweenadjacent markers, thereby indicating the second calibration point. Incertain embodiments, the welding system 10 will only detect acalibration point if the calibration tool 610 is pressed and held at thecalibration point for a predetermine period of time (e.g., 0.1, 0.3,0.5, 1.0, 2.0 seconds, and so forth). The welding system 10 may beconfigured to capture multiple calibration points (e.g., 50, 100, etc.)over the predetermined period of time and average them together. Ifmovement of the multiple calibration points greater than a predeterminedthreshold is detected, the calibration may be rejected and done over.Furthermore, if a first point is successfully calibrated, a second pointmay be required to be a minimum distance away from the first point(e.g., 2, 4, 6 inches, etc.). If the second point is not the minimumdistance away from the first point, calibration of the second point maybe rejected and done over. The welding system 10 uses the twocalibration points to calibrate the workpiece.

In certain embodiments, the welding system 10 may determine a virtualline between the first and second calibration points. The virtual linemay be infinitely long and extend beyond the first and secondcalibration points. The virtual line represents a weld joint. Variouswelding parameters (e.g., work angle, travel angle, contact tip-to-workdistance (CTWD), aim, travel speed, etc.) may be in reference to thisvirtual line. Accordingly, the virtual line may be important forcalculating the various welding parameters.

It should be noted that in certain embodiments the first, second, andthird markers 630, 632, and 638 are all disposed vertically above thehandle 612, while in other embodiments, one or more of the first,second, and third markers 630, 632, and 638 are disposed verticallybelow the handle 612 to enable a greater distance between adjacentmarkers. In certain embodiments, the first portion 624 may be removedfrom the calibration tool 610 and coupled to a contact tip of thewelding torch 14 for calibrating the welding torch 14. As may beappreciated, the tip 614 of the calibration tool 610 may be any suitableshape. FIGS. 43 through 45 illustrate a few embodiments of shapes thetip 614 may have.

Specifically, FIG. 43 is a side view of an embodiment of a pointed tip648 of the calibration tool 610. Using the pointed tip 648, thecalibration tool 610 may be used for calibrating various joints on theworkpiece 82, such as the illustrated fillet joint, a lap joint, a buttjoint with no root opening, and so forth. Moreover, FIG. 44 is a sideview of an embodiment of a rounded tip 650 of the calibration tool 610.Using the rounded tip 650, the calibration tool 610 may be used forcalibrating various joints on the workpiece 82, such as the illustratedfillet joint, a butt joint with a root opening, a lap joint, and soforth. Furthermore, FIG. 45 is a side view of an embodiment of therounded tip 650 of the calibration tool 610 having a small pointed tip652. Using the small pointed tip 652 on the end of the rounded tip 650,the calibration tool 610 may be used for calibrating various joints onthe workpiece 82, such as the illustrated butt joint with no rootopening, a filled joint, a lap joint, and so forth. In certainembodiments, the tip of the calibration tool 610 may be removable and/orreversible, such that the tip includes two different types of tips(e.g., one type of tip on each opposing end). Accordingly, a weldingoperator may select the type of tip used by the calibration tool 610. Incertain embodiments, one or more markers may be coupled to thecalibration tool 610 if the calibration tool 610 is reversible. The oneor more markers may be used to indicate which side of the tip is beingused so that the welding system 10 may use a suitable marker-tipdistance for calibration calculations.

FIG. 46 is an embodiment of a method 654 for detecting a calibrationpoint. The sensing device 16 (or another component of the welding system10) detects a first marker of the calibration tool 610, a second markerof the calibration tool 610, and/or a third marker of the calibrationtool 610 (block 656). Moreover, the welding system 10 determines a firstdistance between the first marker and the second marker and/or a seconddistance between the second marker and the third marker (block 658).Furthermore, the welding system 10 detects whether the first distance orthe second distance is within a predetermined distance range (e.g.,signifying a compressed distance) (block 660).

The welding system 10 determines a position of a calibration point ifthe first distance or the second distance is within the predetermineddistance range (e.g., signifying a compressed distance) (block 662). Inaddition, the welding system 10 determines a location of a calibrationtip of the calibration tool 610 relative to at least one of the first,second, and third markers to determine the spatial position of thecalibration point (block 664).

FIG. 47 is an embodiment of a method 666 for determining a welding scorebased on a welding path. Accordingly, the method 666 may be used forevaluating a welding operation. The sensing device 16 (or any suitablemotion tracking system) detects an initial position of the weldingoperation (block 668). Moreover, the sensing device 16 detects aterminal position of the welding operation (block 670). In addition, thesensing device 16 detects a spatial path of the welding operationbetween the initial position and the terminal position (block 672). Forexample, the sensing device 16 tracks a position and/or an orientationof the welding operation. The welding system 10 determines a score ofthe welding operation based at least partly on the spatial path of thewelding operation (e.g., whether the welding operation receives apassing score based on the spatial path of the welding operation) (block674). For example, in certain embodiments, the spatial path of thewelding operation may alone be used to determine whether a welding scorefails. In some embodiments, the sensing device 16 may be used to detecta calibration point that corresponds to the initial position and/or acalibration point that corresponds to the terminal position.

For example, in certain embodiments, the welding system 10 determineswhether the welding operation receives a passing score by determiningwhether: a distance of the path of the welding operation is greater thana predetermined lower threshold, the distance of the path of the weldingoperation is less than the predetermined lower threshold, the distanceof the path of the welding operation is greater than a predeterminedupper threshold, the distance of the path of the welding operation isless than the predetermined upper threshold, the path of the weldingoperation deviates substantially from a predetermined path of thewelding operation, the path of the welding operation indicates thatmultiple welding passes occurred at a single location along a weldjoint, a time of welding along the path of the welding operation isgreater than a predetermined lower threshold, the time of welding alongthe path of the welding operation is less than the predetermined lowerthreshold, the time of welding along the path of the welding operationis greater than a predetermined upper threshold, and/or the time ofwelding along the path of the welding operation is less than thepredetermined upper threshold.

Moreover, in some embodiments, for the welding system 10 to determine ascore, the welding system 10 may disregard a first portion of the pathadjacent to the initial position and a second portion of the pathadjacent to the terminal position. For example, the first portion of thepath and the second portion of the path may include a distance ofapproximately 0.5 inches. Moreover, in other embodiments, the firstportion of the path and the second portion of the path may includeportions of the path formed during a time of approximately 0.5 seconds.

FIG. 48 is an embodiment of a method 676 for transitioning betweenwelding modes using a user interface of the welding torch 14. Thecontrol circuitry 52 of the welding torch 14 (or control circuitry ofanother device) detects a signal produced by a user interface of thewelding torch 14 indicating a request to change the welding mode (e.g.,welding training mode) (block 678). Moreover, the control circuitry 52determines a length of time that the signal is detected (block 680). Thecontrol circuitry 52 is configured to change the welding mode from asimulation mode (e.g., virtual reality mode, augmented reality mode,etc.) to a live welding mode if the length of time that the signal isdetected is greater than a predetermined threshold (block 682).Conversely, the control circuitry 52 is configured to change the weldingmode from the live welding mode to the simulation mode merely if thesignal is detected (block 684) (e.g., there is no length of time thatthe signal is to be detected before a transition from the live weldingmode is made). The control circuitry 52 is configured to direct thewelding torch 14 to vibrate after changing to the live welding mode(block 686). For example, the control circuitry 52 may be configured todirect the welding torch 14 to vibrate two or more times (e.g.,vibration pulses) to indicate a change to the live welding mode.

Moreover, the control circuitry 52 may be configured to direct thewelding torch 14 to vibrate any suitable number of times (e.g.,predetermined number of times) to indicate a change to the live weldingmode. As may be appreciated, the signal indicating the request to changethe welding mode may be produced by pressing a button on the userinterface of the welding torch 14. As such, the welding mode may bechanged from the live welding mode by pressing and releasing the button(e.g., the button does not have to be held down for a predeterminedperiod of time). In contrast, the welding mode may be changed from thesimulation mode to the live welding mode by pressing and holding thebutton for a predetermined period of time. In certain embodiments, anaudible sound may be produced after changing welding modes. Furthermore,in some embodiments an audible sound and a vibration may accompany anychange between welding modes. In addition, a display of the weldingtorch 14 may show the welding mode after changing the welding mode. Insome embodiments, the display may flash the welding mode on the displaya predetermined number of times.

As mentioned above, the welding voltage 337 and the welding current 338within the welding torch 14 may be one of several parameters measuredduring a welding operation. Various components of the welding system 10then convey information relating to the welding voltage 337 and/or thewelding current 338 to the operator in a variety of ways. For example,the welding voltage 337 and/or the welding current 338 may be shown onthe display 32 and/or the display 62. The welding software 244 may alsocontrol the audio output 256 and the video output 258 to indicate thewelding voltage 337 and/or the welding current 338 (e.g., via a message,as visual indicators 61, etc.). The vibration device 428 may alsoprovide feedback as described above based on the welding voltage 337and/or welding current 338. For instance, if the welding voltage 337 orthe welding current 338 exceeds a threshold, as determined by method478, the vibration device 428 may provide haptic feedback to theoperator.

In certain embodiments, to measure the welding voltage 337 and thewelding current 338, the welding torch 14 includes a voltage sensingcomponent 700 and a current sensing component 702 at least partially,and in some embodiments entirely, disposed within a body (e.g., thehandle 122, in certain embodiments) of the welding torch 14. FIG. 49 isa perspective view of an embodiment of the welding torch 14 withportions of the handle 122 of the welding torch 14 removed forillustration purposes. As illustrated in FIG. 49, the voltage sensingcomponent 700 is coupled to the welding conductor 74, while the currentsensing component 702 is mounted near the welding conductor 74. Althoughthe voltage sensing component 700 and the current sensing component 702are described in relation to the welding conductor 74, it should beappreciated that the voltage sensing component 700 and the currentsensing component 702 may be proximate to the welding conductor 76 (seeFIG. 2 and related description) in other embodiments. That is, in otherembodiments, the voltage sensing component 700 may be coupled to thewelding conductor 76 and the current sensing component 702 may bemounted near the welding conductor 76. In still other embodiments, thevoltage sensing component 700 may be coupled to the welding conductor 74and the current sensing component 702 may be mounted near the weldingcomponent 76, or vice versa. Furthermore, in yet other embodiments, onlyone of the voltage sensing component 700 or the current sensingcomponent 702 may be used, and may be coupled to either of the weldingconductors 74, 76.

In certain embodiments, the voltage sensing component 700 includes aconductor 704, a first lead 706, and a second lead 708. The conductor704 may be any suitable conductive material, such as copper and aluminumand may be electrically coupled to the second lead 708. As shown in FIG.50, the first lead 706 may be electrically coupled to the weldingconductor 74. For example, in certain embodiments, the first lead 706 iscoupled to a cone nut 710 within the welding torch 14, and the cone nut710 is electrically coupled to the welding conductor 74. The second lead708 may be configured to electrically couple to conductive materials onvarious components of the welding system 10 (e.g., the work cable 84,the stand 12, a non-welding surface of the workpiece 82, etc.). Forexample, in certain embodiments, as shown in FIG. 50, the second lead708 may extend out of the welding torch 14 as a pig tail that can thenbe coupled to other conductors within the welding system 10. As aresult, a voltage across the welding conductor 74 may appear on thefirst lead 706 and a voltage across the conductor 704 may appear on thesecond lead 708.

The voltage sensing component 700 also includes circuitry 712 thatreceives the voltages from the first lead 706 and the second lead 708.The circuitry 712 determines the welding voltage 337 by computing adifference between the voltages from the first lead 706 (i.e., thewelding conductor 74) and the second lead 708 (i.e., the conductor 704).The circuitry 712 then converts (e.g., scales) the welding voltage 337into an output signal appropriate for an input to processing system,such as a microcontroller, the control circuitry 52, the computer system18, and the like. FIG. 51 depicts a schematic of the circuitry 712 that,in the illustrated embodiment, scales the welding voltage 337 to asignal suitable for an input to a microcontroller. As will beappreciated, the configuration of the circuitry 712 may vary based onthe particular application. Further, in certain embodiments, thecircuitry 712 may be configured to convert (e.g., scale) the weldingvoltage 337 based on the welding operation being performed and/or thesystem (e.g., a microcontroller, the computer system 18, etc.) receivingthe input from the circuitry 712.

Turning now to FIG. 52, in certain embodiments, the current sensingcomponent 702 includes a Hall sensor 714 mounted near the weldingconductor 704. As one skilled in the art would appreciate, the weldingcurrent 338 causes a magnetic field 720. As illustrated in FIG. 53, themagnetic field 720 passes through the Hall sensor 714, which measures amagnetic flux of the magnetic field 720. Using the magnetic flux of themagnetic field 720, the Hall sensor 714 may determine a Hall voltage722. The Hall voltage 722 may appear at a right angle (e.g., generatedradially outward from the welding conductor 74) to the welding current338 and is directly proportional to the welding current 338. Further, insome embodiments, the Hall sensor 714 may be disposed within a highlypermeable magnetic material 716, as shown in FIG. 53. The highlypermeable magnetic material 716 may concentrate the magnetic flux of themagnetic field 720, thereby increasing the amount of the magnetic field720 measured by the Hall sensor 714.

The current sensing component 702 also includes circuitry 724 thatreceives the Hall voltage 722 from the Hall sensor 714 and converts(e.g., scales) the Hall voltage 722 into an output signal suitable foruse in a manner similar to how the circuitry 712 converts (e.g., scales)the welding voltage 337, and transmits the output signal to a processingsystem, such as a microcontroller, the control circuitry 52, thecomputer system 18, and the like. FIG. 54 depicts a schematic of thecurrent sensing component 702 that, in the illustrated embodiment,measures the Hall voltage 722 and scales the Hall voltage 722 to a levelsuitable for input to a microcontroller. The microcontroller (not shown)then determines the welding current 338 based on the scaled Hall voltage722. It should be noted that although the current sensing component 702is described herein as using a Hall sensor 714, in other embodiments,the current sensing component 702 may use other magnetic and/or currentsensors in conjunction with the circuitry 724.

As mentioned above, the Hall voltage 722 is generated at a right angle(e.g., generated radially outward from a cylindrical conductor 74) tothe welding current 338, which generally flows parallel to the weldingconductor 74. As a result, the current sensing component 702, asillustrated in FIG. 55, is mounted such that a surface of the Hallsensor 714 is orthogonal to the magnetic field 720 of the weldingcurrent 338, in order to measure the Hall voltage 722. In theillustrated embodiment, the current sensing component 702 is a printedcircuit board (PCB) 726 that includes the circuitry 724 and the Hallsensor 714, which may be a surface mount or leaded device. In certainembodiments, the PCB 726 is soldered to the cone nut 710 to secure thePCB 726 in its position relative to the welding conductor 74. In otherembodiments, the PCB 726 may be coupled via a screw to a conductivestrap, which in turn may be coupled to the cone nut 710. Alternately oradditionally, the PCB 726 may be coupled to other pieces of hardwarewithin the welding torch 14.

In certain embodiments, it may not be desirable to have the entirecurrent sensing component 702 mounted at a right angle to the weldingconductor 704. For example, there may be space constraints due to othercomponents in the welding torch 14 that affect the position of thecurrent sensing component 702. In such embodiments, the Hall sensor 714may be a standalone device communicatively coupled to the PCB 726. Insuch an embodiment, the Hall sensor 714 may still be orientatedorthogonally to the magnetic field 720 of the welding current 338, evenif the PCB 726 is not. For instance, FIG. 56 depicts the Hall sensor 714coupled to a ferrite core 728, which may be disposed (e.g., radially)around the welding conductor 74. In other embodiments, the Hall sensor714 may be fastened to the cone nut 710 using an adhesive. So long asthe Hall sensor 714 is communicatively coupled to the PCB 726, the Hallsensor 714 can maintain its orientation orthogonally to the magneticfield 720 of the welding current 338 even when the PCB 726 does not.

As mentioned above, the welding system 10 may use the measured weldingvoltage 337 and welding current 338 in a variety of ways. However,although the welding system 10 is described herein as a training system,it should be appreciated that the voltage sensing component 700 and thecurrent sensing component 702 may be used in any suitable welding orplasma cutting system. In certain embodiments, the voltage sensingcomponent 700 and the current sensing component 702 may be provided inthe form of a retrofit kit 730. The retrofit kit 730, as shown in FIG.57, may be a module configured to be installed into any existing weldingtorch 14 in which the corresponding welding system 10 has a means ofrelaying the welding voltage 337 and the welding current 338 to theoperator. For example, the retrofit kit 730 may be installed in weldingsystems 10 that include a welding power supply 28 that is not configuredto measure the current or voltage within the welding power supply 28.After installation of the retrofit kit 730 (e.g., at least partiallywithin a body of the welding torch 14), the operator may then make anynecessary changes to the welding system 10, such as coupling the secondlead 708 to a conductor (e.g., the work cable 84, the stand 12, anon-welding surface of the workpiece 82, and so forth) of the weldingsystem 10 via a pig tail lead or any changes to the welding software244.

As may be appreciated, using the systems, devices, and techniquesdescribed herein, a welding system 10 may be provided for trainingwelding operators. The welding system 10 may be cost efficient and mayenable welding students to receive high quality hands on training.

As used herein, the term “predetermined range” may mean any of thefollowing: a group of numbers bounded by a predetermined upper limit anda predetermined lower limit, a group of number greater than apredetermined limit, and a group of numbers less than a predeterminedlimit. Moreover, the range may include numbers equal to the one or morepredetermined limits.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

1. A welding or plasma cutting torch, comprising: a voltage sensingcomponent at least partially disposed within a body of the welding orplasma cutting torch and comprising voltage sensing circuitry, whereinthe voltage sensing component is configured to measure a welding orplasma cutting voltage of the welding or plasma cutting torch.
 2. Thewelding or plasma cutting torch of claim 1, wherein the voltage sensingcircuitry is configured to convert the measured welding or plasmacutting voltage into an output signal, and to transmit the output signalto a processing system.
 3. The welding or plasma cutting torch of claim1, wherein a welding or plasma cutting system comprises the welding orplasma cutting torch.
 4. The welding or plasma cutting torch of claim 3,wherein the welding or plasma cutting system comprises a trainingsystem.
 5. The welding or plasma cutting torch of claim 3, wherein thewelding or plasma cutting system comprises a power source that is notconfigured to measure a current or a voltage within the power source. 6.The welding or plasma cutting torch of claim 1, wherein the welding orplasma cutting torch comprises a first conductor configured to convey acurrent through a torch head of the welding or plasma cutting torch,wherein the voltage sensing component comprises a second conductor, andwherein the voltage sensing component is configured to measure adifference between a first voltage of the first conductor and a secondvoltage of the second conductor, wherein the difference is the weldingor plasma cutting voltage.
 7. The welding or plasma cutting torch ofclaim 1, comprising a current sensing component at least partiallydisposed within the body of the welding or plasma cutting torch andcomprising current sensing circuitry, wherein the current sensingcomponent is configured to measure a welding or plasma cutting currentof the welding or plasma cutting torch.
 8. The welding or plasma cuttingtorch of claim 7, wherein the current sensing component comprises amagnetic sensor.
 9. The welding or plasma cutting torch of claim 8,wherein the magnetic sensor is a Hall sensor.
 10. The welding or plasmacutting torch of claim 1, comprising a retrofit module having thevoltage sensing component and configured to be retrofit into the weldingor plasma cutting torch.
 11. A welding or plasma cutting torch,comprising: a current sensing component at least partially disposedwithin a body of the welding or plasma cutting torch and comprisingcurrent sensing circuitry, wherein the current sensing component isconfigured to measure a welding or plasma cutting current of the weldingor plasma cutting torch.
 12. The welding or plasma cutting torch ofclaim 11, wherein the current sensing circuitry is configured to convertthe measured welding or plasma cutting current into an output signal,and to transmit the output signal to a processing system.
 13. Thewelding or plasma cutting torch of claim 11, wherein a welding or plasmacutting system comprises the welding or plasma cutting torch.
 14. Thewelding or plasma cutting torch of claim 11, wherein the current sensingcomponent comprises a magnetic sensor.
 15. The welding or plasma cuttingtorch of claim 14, wherein the magnetic sensor comprises a Hall sensor.16. The welding or plasma cutting torch of claim 15, wherein the currentsensing component is disposed on a printed circuit board (PCB), andwherein a surface of the Hall sensor is disposed orthogonally to amagnetic field caused by the welding or plasma cutting current.
 17. Thewelding or plasma cutting torch of claim 15, comprising a welding orplasma cutting conductor configured to convey the welding or plasmacutting current through a torch head of the welding or plasma cuttingtorch, wherein the current sensing component is disposed within aferrite core, and wherein the ferrite core is disposed around thewelding or plasma cutting conductor.
 18. The welding or plasma cuttingtorch of claim 11, comprising a retrofit module having the currentsensing component and configured to be retrofit into the welding orplasma cutting torch.
 19. The welding or plasma cutting torch of claim11, comprising a voltage sensing component at least partially disposedwithin the body of the welding or plasma cutting torch and comprisingvoltage sensing circuitry, wherein the voltage sensing component isconfigured to measure a welding or plasma cutting voltage of the weldingor plasma cutting torch.
 20. A retrofit module, comprising at least oneof: a current sensing component comprising a first circuit; or a voltagesensing component comprising a second circuit; wherein the currentsensing component and the voltage sensing component are configured to bedisposed in a torch head of a welding or plasma cutting torch, whereinthe current sensing component is configured to measure a welding orplasma cutting current of the torch head, and wherein the voltagesensing component is configured to measure a welding or plasma cuttingvoltage of the torch head.